Expandable Tubular

ABSTRACT

An expandable tubular member.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is the U.S. National Stage application for PCTapplication serial no. PCT/US2004/029025, attorney docket no.25791.306.02, filed on Sep. 7, 2004, which claimed the benefit of thefiling date of: a) U.S. provisional patent application Ser. No.60/600,679, attorney docket number 25791.194, filed on Aug. 11, 2004,the disclosure which is incorporated herein by reference; b) U.S.provisional patent application Ser. No. 60/585,370, attorney docketnumber 25791.299, filed on Jul. 2, 2004, the disclosure which isincorporated herein by reference; and c) U.S. provisional patentapplication Ser. No. 60/500,435, attorney docket number 25791.304, filedon Sep. 5, 2003, the disclosure which is incorporated herein byreference.

The application is a continuation-in-part of U.S. utility patentapplication Ser. No. 10/528,498, attorney docket no. 25791.118.08, filedon Mar. 18, 2005, which was the National Stage for PCT applicationserial no. PCT/US03/025667, attorney docket no. 25791.118.02, filed onAug. 18, 2003, which claimed the benefit of the filing date of U.S.provisional patent application Ser. No. 60/412,653, attorney docket25791.118, filed on Sep. 20, 2002, the disclosures of which areincorporated herein by reference.

This application is related to the following co-pending applications:(1) U.S. National State patent application Ser. No. ______, attorneydocket no. 25791.304.10, filed on Mar. 2, 2006; (2) U.S. National Statepatent application Ser. No. ______, attorney docket no. 25791.305.05,filed on ______; (3) U.S. National State patent application Ser. No.______, attorney docket no. 25791.307.04, filed on ______; and (4) U.S.National State patent application Ser. No. ______, attorney docket no.25791.308.07, filed on ______, the disclosures of which are incorporatedherein by reference.

This application is related to the following co-pending applications:(1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent applicationSer. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3,1999, which claims priority from provisional application 60/111,293,filed on Dec. 7, 1998, (2) U.S. patent application Ser. No. 09/510,913,attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimspriority from provisional application 60/121,702, filed on Feb. 25,1999, (3) U.S. patent application Ser. No. 09/502,350, attorney docketno. 25791.8.02, filed on Feb. 10, 2000, which claims priority fromprovisional application 60/119,611, filed on Feb. 11, 1999, (4) U.S.Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No.09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999,which claims priority from provisional application 60/108,558, filed onNov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434, attorneydocket no. 25791.10.04, filed on Jul. 1, 2002, which claims priorityfrom provisional application 60/183,546, filed on Feb. 18, 2000, (6)U.S. Pat. No. 6,640,903 which was filed as U.S. patent application Ser.No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claims priority from provisional application 60/124,042, filed onMar. 11, 1999, (7) U.S. Pat. No. 6,568,471, which was filed as patentapplication Ser. No. 09/512,895, attorney docket no. 25791.12.02, filedon Feb. 24, 2000, which claims priority from provisional application60/121,841, filed on Feb. 26, 1999, (8) U.S. Pat. No. 6,575,240, whichwas filed as patent application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claims priority fromprovisional application 60/121,907, filed on Feb. 26, 1999, (9) U.S.Pat. No. 6,557,640, which was filed as patent application Ser. No.09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,which claims priority from provisional application 60/137,998, filed onJun. 7, 1999, (10) U.S. patent application Ser. No. 09/981,916, attorneydocket no. 25791.18, filed on Oct. 18, 2001 as a continuation-in-partapplication of U.S. Pat. No. 6,328,113, which was filed as U.S. patentapplication Ser. No. 09/440,338, attorney docket number 25791.9.02,filed on Nov. 15, 1999, which claims priority from provisionalapplication 60/108,558, filed on Nov. 16, 1998, (11) U.S. Pat. No.6,604,763, which was filed as application Ser. No. 09/559,122, attorneydocket no. 25791.23.02, filed on Apr. 26, 2000, which claims priorityfrom provisional application 60/131,106, filed on Apr. 26, 1999, (12)U.S. patent application Ser. No. 10/030,593, attorney docket no.25791.25.08, filed on Jan. 8, 2002, which claims priority fromprovisional application 60/146,203, filed on Jul. 29, 1999, (13) U.S.provisional patent application Ser. No. 60/143,039, attorney docket no.25791.26, filed on Jul. 9, 1999, (14) U.S. patent application Ser. No.10/111,982, attorney docket no. 25791.27.08, filed on Apr. 30, 2002,which claims priority from provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999, (15)U.S. provisional patent application Ser. No. 60/154,047, attorney docketno. 25791.29, filed on Sep. 16, 1999, (16) U.S. provisional patentapplication Ser. No. 60/438,828, attorney docket no. 25791.31, filed onJan. 9, 2003, (17) U.S. Pat. No. 6,564,875, which was filed asapplication Ser. No. 09/679,907, attorney docket no. 25791.34.02, onOct. 5, 2000, which claims priority from provisional patent applicationSer. No. 60/159,082, attorney docket no. 25791.34, filed on Oct. 12,1999, (18) U.S. patent application Ser. No. 10/089,419, filed on Mar.27, 2002, attorney docket no. 25791.36.03, which claims priority fromprovisional patent application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999, (19) U.S. patent application Ser. No.09/679,906, filed on Oct. 5, 2000, attorney docket no. 25791.37.02,which claims priority from provisional patent application Ser. No.60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999, (20)U.S. patent application Ser. No. 10/303,992, filed on Nov. 22, 2002,attorney docket no. 25791.38.07, which claims priority from provisionalpatent application Ser. No. 60/212,359, attorney docket no. 25791.38,filed on Jun. 19, 2000, (21) U.S. provisional patent application Ser.No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999,(22) U.S. provisional patent application Ser. No. 60/455,051, attorneydocket no. 25791.40, filed on Mar. 14, 2003, (23) PCT applicationUS02/2477, filed on Jun. 26, 2002, attorney docket no. 25791.44.02,which claims priority from U.S. provisional patent application Ser. No.60/303,711, attorney docket no. 25791.44, filed on Jul. 6, 2001, (24)U.S. patent application Ser. No. 10/311,412, filed on Dec. 12, 2002,attorney docket no. 25791.45.07, which claims priority from provisionalpatent application Ser. No. 60/221,443, attorney docket no. 25791.45,filed on Jul. 28, 2000, (25) U.S. patent application Ser. No. 10/, filedon Dec. 18, 2002, attorney docket no. 25791.46.07, which claims priorityfrom provisional patent application Ser. No. 60/221,645, attorney docketno. 25791.46, filed on Jul. 28, 2000, (26) U.S. patent application Ser.No. 10/322,947, filed on Jan. 22, 2003, attorney docket no. 25791.47.03,which claims priority from provisional patent application Ser. No.60/233,638, attorney docket no. 25791.47, filed on Sep. 18, 2000, (27)U.S. patent application Ser. No. 10/406,648, filed on Mar. 31, 2003,attorney docket no. 25791.48.06, which claims priority from provisionalpatent application Ser. No. 60/237,334, attorney docket no. 25791.48,filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on Feb.14, 2002, attorney docket no. 25791.50.02, which claims priority fromU.S. provisional patent application Ser. No. 60/270,007, attorney docketno. 25791.50, filed on Feb. 20, 2001, (29) U.S. patent application Ser.No. 10/465,835, filed on Jun. 13, 2003, attorney docket no. 25791.51.06,which claims priority from provisional patent application Ser. No.60/262,434, attorney docket no. 25791.51, filed on Jan. 17, 2001, (30)U.S. patent application Ser. No. 10/465,831, filed on Jun. 13, 2003,attorney docket no. 25791.52.06, which claims priority from U.S.provisional patent application Ser. No. 60/259,486, attorney docket no.25791.52, filed on Jan. 3, 2001, (31) U.S. provisional patentapplication Ser. No. 60/452,303, filed on Mar. 5, 2003, attorney docketno. 25791.53, (32) U.S. Pat. No. 6,470,966, which was filed as patentapplication Ser. No. 09/850,093, filed on May 7, 2001, attorney docketno. 25791.55, as a divisional application of U.S. Pat. No. 6,497,289,which was filed as U.S. patent application Ser. No. 09/454,139, attorneydocket no. 25791.03.02, filed on Dec. 3, 1999, which claims priorityfrom provisional application 60/111,293, filed on Dec. 7, 1998, (33)U.S. Pat. No. 6,561,227, which was filed as patent application Ser. No.09/852,026, filed on May 9, 2001, attorney docket no. 25791.56, as adivisional application of U.S. Pat. No. 6,497,289, which was filed asU.S. patent application Ser. No. 09/454,139, attorney docket no.25791.03.02, filed on Dec. 3, 1999, which claims priority fromprovisional application 60/111,293, filed on Dec. 7, 1998, (34) U.S.patent application Ser. No. 09/852,027, filed on May 9, 2001, attorneydocket no. 25791.57, as a divisional application of U.S. Pat. No.6,497,289, which was filed as U.S. patent application Ser. No.09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,which claims priority from provisional application 60/111,293, filed onDec. 7, 1998, (35) PCT Application US02/25608, attorney docket no.25791.58.02, filed on Aug. 13, 2002, which claims priority fromprovisional application 60/318,021, filed on Sep. 7, 2001, attorneydocket no. 25791.58, (36) PCT Application US02/24399, attorney docketno. 25791.59.02, filed on Aug. 1, 2002, which claims priority from U.S.provisional patent application Ser. No. 60/313,453, attorney docket no.25791.59, filed on Aug. 20, 2001, (37) PCT Application US02/29856,attorney docket no. 25791.60.02, filed on Sep. 19, 2002, which claimspriority from U.S. provisional patent application Ser. No. 60/326,886,attorney docket no. 25791.60, filed on Oct. 3, 2001, (38) PCTApplication US02/20256, attorney docket no. 25791.61.02, filed on Jun.26, 2002, which claims priority from U.S. provisional patent applicationSer. No. 60/303,740, attorney docket no. 25791.61, filed on Jul. 6,2001, (39) U.S. patent application Ser. No. 09/962,469, filed on Sep.25, 2001, attorney docket no. 25791.62, which is a divisional of U.S.patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02,filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903 which issued Nov.4, 2003), which claims priority from provisional application 60/124,042,filed on Mar. 11, 1999, (40) U.S. patent application Ser. No.09/962,470, filed on Sep. 25, 2001, attorney docket no. 25791.63, whichis a divisional of U.S. patent application Ser. No. 09/523,468, attorneydocket no. 25791.11.02, filed on Mar. 10, 2000, (now U.S. Pat. No.6,640,903 which issued Nov. 4, 2003), which claims priority fromprovisional application 60/124,042, filed on Mar. 11, 1999, (41) U.S.patent application Ser. No. 09/962,471, filed on Sep. 25, 2001, attorneydocket no. 25791.64, which is a divisional of U.S. patent applicationSer. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10,2000, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003), whichclaims priority from provisional application 60/124,042, filed on Mar.11, 1999, (42) U.S. patent application Ser. No. 09/962,467, filed onSep. 25, 2001, attorney docket no. 25791.65, which is a divisional ofU.S. patent application Ser. No. 09/523,468, attorney docket no.25791.11.02, filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903 whichissued Nov. 4, 2003), which claims priority from provisional application60/124,042, filed on Mar. 11, 1999, (43) U.S. patent application Ser.No. 09/962,468, filed on Sep. 25, 2001, attorney docket no. 25791.66,which is a divisional of U.S. patent application Ser. No. 09/523,468,attorney docket no. 25791.11.02, filed on Mar. 10, 2000, (now U.S. Pat.No. 6,640,903 which issued Nov. 4, 2003), which claims priority fromprovisional application 60/124,042, filed on Mar. 11, 1999, (44) PCTapplication US 02/25727, filed on Aug. 14, 2002, attorney docket no.25791.67.03, which claims priority from U.S. provisional patentapplication Ser. No. 60/317,985, attorney docket no. 25791.67, filed onSep. 6, 2001, and U.S. provisional patent application Ser. No.60/318,386, attorney docket no. 25791.67.02, filed on Sep. 10, 2001,(45) PCT application US 02/39425, filed on Dec. 10, 2002, attorneydocket no. 25791.68.02, which claims priority from U.S. provisionalpatent application Ser. No. 60/343,674, attorney docket no. 25791.68,filed on Dec. 27, 2001, (46) U.S. utility patent application Ser. No.09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001, (nowU.S. Pat. No. 6,634,431 which issued Oct. 21, 2003), which is acontinuation-in-part application of U.S. Pat. No. 6,328,113, which wasfiled as U.S. patent application Ser. No. 09/440,338, attorney docketnumber 25791.9.02, filed on Nov. 15, 1999, which claims priority fromprovisional application 60/108,558, filed on Nov. 16, 1998, (47) U.S.utility patent application Ser. No. 10/516,467, attorney docket no.25791.70, filed on Dec. 10, 2001, which is a continuation application ofU.S. utility patent application Ser. No. 09/969,922, attorney docket no.25791.69, filed on Oct. 3, 2001, (now U.S. Pat. No. 6,634,431 whichissued Oct. 21, 2003), which is a continuation-in-part application ofU.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser.No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15,1999, which claims priority from provisional application 60/108,558,filed on Nov. 16, 1998, (48) PCT application US 03/00609, filed on Jan.9, 2003, attorney docket no. 25791.71.02, which claims priority fromU.S. provisional patent application Ser. No. 60/357,372, attorney docketno. 25791.71, filed on Feb. 15, 2002, (49) U.S. patent application Ser.No. 10/074,703, attorney docket no. 25791.74, filed on Feb. 12, 2002,which is a divisional of U.S. Pat. No. 6,568,471, which was filed aspatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claims priority from provisionalapplication 60/121,841, filed on Feb. 26, 1999, (50) U.S. patentapplication Ser. No. 10/074,244, attorney docket no. 25791.75, filed onFeb. 12, 2002, which is a divisional of U.S. Pat. No. 6,568,471, whichwas filed as patent application Ser. No. 09/512,895, attorney docket no.25791.12.02, filed on Feb. 24, 2000, which claims priority fromprovisional application 60/121,841, filed on Feb. 26, 1999, (51) U.S.patent application Ser. No. 10/076,660, attorney docket no. 25791.76,filed on Feb. 15, 2002, which is a divisional of U.S. Pat. No.6,568,471, which was filed as patent application Ser. No. 09/512,895,attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimspriority from provisional application 60/121,841, filed on Feb. 26,1999, (52) U.S. patent application Ser. No. 10/076,661, attorney docketno. 25791.77, filed on Feb. 15, 2002, which is a divisional of U.S. Pat.No. 6,568,471, which was filed as patent application Ser. No.09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000,which claims priority from provisional application 60/121,841, filed onFeb. 26, 1999, (53) U.S. patent application Ser. No. 10/076,659,attorney docket no. 25791.78, filed on Feb. 15, 2002, which is adivisional of U.S. Pat. No. 6,568,471, which was filed as patentapplication Ser. No. 09/512,895, attorney docket no. 25791.12.02, filedon Feb. 24, 2000, which claims priority from provisional application60/121,841, filed on Feb. 26, 1999, (54) U.S. patent application Ser.No. 10/078,928, attorney docket no. 25791.79, filed on Feb. 20, 2002,which is a divisional of U.S. Pat. No. 6,568,471, which was filed aspatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claims priority from provisionalapplication 60/121,841, filed on Feb. 26, 1999, (55) U.S. patentapplication Ser. No. 10/078,922, attorney docket no. 25791.80, filed onFeb. 20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, whichwas filed as patent application Ser. No. 09/512,895, attorney docket no.25791.12.02, filed on Feb. 24, 2000, which claims priority fromprovisional application 60/121,841, filed on Feb. 26, 1999, (56) U.S.patent application Ser. No. 10/078,921, attorney docket no. 25791.81,filed on Feb. 20, 2002, which is a divisional of U.S. Pat. No.6,568,471, which was filed as patent application Ser. No. 09/512,895,attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimspriority from provisional application 60/121,841, filed on Feb. 26,1999, (57) U.S. patent application Ser. No. 10/261,928, attorney docketno. 25791.82, filed on Oct. 1, 2002, which is a divisional of U.S. Pat.No. 6,557,640, which was filed as patent application Ser. No.09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,which claims priority from provisional application 60/137,998, filed onJun. 7, 1999, (58) U.S. patent application Ser. No. 10/079,276, attorneydocket no. 25791.83, filed on Feb. 20, 2002, which is a divisional ofU.S. Pat. No. 6,568,471, which was filed as patent application Ser. No.09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000,which claims priority from provisional application 60/121,841, filed onFeb. 26, 1999, (59) U.S. patent application Ser. No. 10/262,009,attorney docket no. 25791.84, filed on Oct. 1, 2002, which is adivisional of U.S. Pat. No. 6,557,640, which was filed as patentapplication Ser. No. 09/588,946, attorney docket no. 25791.17.02, filedon Jun. 7, 2000, which claims priority from provisional application60/137,998, filed on Jun. 7, 1999, (60) U.S. patent application Ser. No.10/092,481, attorney docket no. 25791.85, filed on Mar. 7, 2002, whichis a divisional of U.S. Pat. No. 6,568,471, which was filed as patentapplication Ser. No. 09/512,895, attorney docket no. 25791.12.02, filedon Feb. 24, 2000, which claims priority from provisional application60/121,841, filed on Feb. 26, 1999, (61) U.S. patent application Ser.No. 10/261,926, attorney docket no. 25791.86, filed on Oct. 1, 2002,which is a divisional of U.S. Pat. No. 6,557,640, which was filed aspatent application Ser. No. 09/588,946, attorney docket no. 25791.17.02,filed on Jun. 7, 2000, which claims priority from provisionalapplication 60/137,998, filed on Jun. 7, 1999, (62) PCT application US02/36157, filed on Nov. 12, 2002, attorney docket no. 25791.87.02, whichclaims priority from U.S. provisional patent application Ser. No.60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001, (63)PCT application US 02/36267, filed on Nov. 12, 2002, attorney docket no.25791.88.02, which claims priority from U.S. provisional patentapplication Ser. No. 60/339,013, attorney docket no. 25791.88, filed onNov. 12, 2001, (64) PCT application US 03/11765, filed on Apr. 16, 2003,attorney docket no. 25791.89.02, which claims priority from U.S.provisional patent application Ser. No. 60/383,917, attorney docket no.25791.89, filed on May 29, 2002, (65) PCT application US 03/15020, filedon May 12, 2003, attorney docket no. 25791.90.02, which claims priorityfrom U.S. provisional patent application Ser. No. 60/391,703, attorneydocket no. 25791.90, filed on Jun. 26, 2002, (66) PCT application US02/39418, filed on Dec. 10, 2002, attorney docket no. 25791.92.02, whichclaims priority from U.S. provisional patent application Ser. No.60/346,309, attorney docket no. 25791.92, filed on Jan. 7, 2002, (67)PCT application US 03/06544, filed on Mar. 4, 2003, attorney docket no.25791.93.02, which claims priority from U.S. provisional patentapplication Ser. No. 60/372,048, attorney docket no. 25791.93, filed onApr. 12, 2002, (68) U.S. patent application Ser. No. 10/331,718,attorney docket no. 25791.94, filed on Dec. 30, 2002, which is adivisional U.S. patent application Ser. No. 09/679,906, filed on Oct. 5,2000, attorney docket no. 25791.37.02, which claims priority fromprovisional patent application Ser. No. 60/159,033, attorney docket no.25791.37, filed on Oct. 12, 1999, (69) PCT application US 03/04837,filed on Feb. 29, 2003, attorney docket no. 25791.95.02, which claimspriority from U.S. provisional patent application Ser. No. 60/363,829,attorney docket no. 25791.95, filed on Mar. 13, 2002, (70) U.S. patentapplication Ser. No. 10/261,927, attorney docket no. 25791.97, filed onOct. 1, 2002, which is a divisional of U.S. Pat. No. 6,557,640, whichwas filed as patent application Ser. No. 09/588,946, attorney docket no.25791.17.02, filed on Jun. 7, 2000, which claims priority fromprovisional application 60/137,998, filed on Jun. 7, 1999, (71) U.S.patent application Ser. No. 10/262,008, attorney docket no. 25791.98,filed on Oct. 1, 2002, which is a divisional of U.S. Pat. No. 6,557,640,which was filed as patent application Ser. No. 09/588,946, attorneydocket no. 25791.17.02, filed on Jun. 7, 2000, which claims priorityfrom provisional application 60/137,998, filed on Jun. 7, 1999, (72)U.S. patent application Ser. No. 10/261,925, attorney docket no.25791.99, filed on Oct. 1, 2002, which is a divisional of U.S. Pat. No.6,557,640, which was filed as patent application Ser. No. 09/588,946,attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimspriority from provisional application 60/137,998, filed on Jun. 7, 1999,(73) U.S. patent application Ser. No. 10/199,524, attorney docket no.25791.100, filed on Jul. 19, 2002, which is a continuation of U.S. Pat.No. 6,497,289, which was filed as U.S. patent application Ser. No.09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,which claims priority from provisional application 60/111,293, filed onDec. 7, 1998, (74) PCT application US 03/10144, filed on Mar. 28, 2003,attorney docket no. 25791.101.02, which claims priority from U.S.provisional patent application Ser. No. 60/372,632, attorney docket no.25791.101, filed on Apr. 15, 2002, (75) U.S. provisional patentapplication Ser. No. 60/412,542, attorney docket no. 25791.102, filed onSep. 20, 2002, (76) PCT application US 03/14153, filed on May 6, 2003,attorney docket no. 25791.104.02, which claims priority from U.S.provisional patent application Ser. No. 60/380,147, attorney docket no.25791.104, filed on May 6, 2002, (77) PCT application US 03/19993, filedon Jun. 24, 2003, attorney docket no. 25791.106.02, which claimspriority from U.S. provisional patent application Ser. No. 60/397,284,attorney docket no. 25791.106, filed on Jul. 19, 2002, (78) PCTapplication US 03/13787, filed on May 5, 2003, attorney docket no.25791.107.02, which claims priority from U.S. provisional patentapplication Ser. No. 60/387,486, attorney docket no. 25791.107, filed onJun. 10, 2002, (79) PCT application US 03/18530, filed on Jun. 11, 2003,attorney docket no. 25791.108.02, which claims priority from U.S.provisional patent application Ser. No. 60/387,961, attorney docket no.25791.108, filed on Jun. 12, 2002, (80) PCT application US 03/20694,filed on Jul. 1, 2003, attorney docket no. 25791.110.02, which claimspriority from U.S. provisional patent application Ser. No. 60/398,061,attorney docket no. 25791.110, filed on Jul. 24, 2002, (81) PCTapplication US 03/20870, filed on Jul. 2, 2003, attorney docket no.25791.111.02, which claims priority from U.S. provisional patentapplication Ser. No. 60/399,240, attorney docket no. 25791.111, filed onJul. 29, 2002, (82) U.S. provisional patent application Ser. No.60/412,487, attorney docket no. 25791.112, filed on Sep. 20, 2002, (83)U.S. provisional patent application Ser. No. 60/412,488, attorney docketno. 25791.114, filed on Sep. 20, 2002, (84) U.S. patent application Ser.No. 10/280,356, attorney docket no. 25791.115, filed on Oct. 25, 2002,which is a continuation of U.S. Pat. No. 6,470,966, which was filed aspatent application Ser. No. 09/850,093, filed on May 7, 2001, attorneydocket no. 25791.55, as a divisional application of U.S. Pat. No.6,497,289, which was filed as U.S. patent application Ser. No.09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,which claims priority from provisional application 60/111,293, filed onDec. 7, 1998, (85) U.S. provisional patent application Ser. No.60/412,177, attorney docket no. 25791.117, filed on Sep. 20, 2002, (86)U.S. provisional patent application Ser. No. 60/412,653, attorney docketno. 25791.118, filed on Sep. 20, 2002, (87) U.S. provisional patentapplication Ser. No. 60/405,610, attorney docket no. 25791.119, filed onAug. 23, 2002, (88) U.S. provisional patent application Ser. No.60/405,394, attorney docket no. 25791.120, filed on Aug. 23, 2002, (89)U.S. provisional patent application Ser. No. 60/412,544, attorney docketno. 25791.121, filed on Sep. 20, 2002, (90) PCT application US 03/24779,filed on Aug. 8, 2003, attorney docket no. 25791.125.02, which claimspriority from U.S. provisional patent application Ser. No. 60/407,442,attorney docket no. 25791.125, filed on Aug. 30, 2002, (91) U.S.provisional patent application Ser. No. 60/423,363, attorney docket no.25791.126, filed on Dec. 10, 2002, (92) U.S. provisional patentapplication Ser. No. 60/412,196, attorney docket no. 25791.127, filed onSep. 20, 2002, (93) U.S. provisional patent application Ser. No.60/412,187, attorney docket no. 25791.128, filed on Sep. 20, 2002, (94)U.S. provisional patent application Ser. No. 60/412,371, attorney docketno. 25791.129, filed on Sep. 20, 2002, (95) U.S. patent application Ser.No. 10/382,325, attorney docket no. 25791.145, filed on Mar. 5, 2003,which is a continuation of U.S. Pat. No. 6,557,640, which was filed aspatent application Ser. No. 09/588,946, attorney docket no. 25791.17.02,filed on Jun. 7, 2000, which claims priority from provisionalapplication 60/137,998, filed on Jun. 7, 1999, (96) U.S. patentapplication Ser. No. 10/624,842, attorney docket no. 25791.151, filed onJul. 22, 2003, which is a divisional of U.S. patent application Ser. No.09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000,which claims priority from provisional application 60/119,611, filed onFeb. 11, 1999, (97) U.S. provisional patent application Ser. No.60/431,184, attorney docket no. 25791.157, filed on Dec. 5, 2002, (98)U.S. provisional patent application Ser. No. 60/448,526, attorney docketno. 25791.185, filed on Feb. 18, 2003, (99) U.S. provisional patentapplication Ser. No. 60/461,539, attorney docket no. 25791.186, filed onApr. 9, 2003, (100) U.S. provisional patent application Ser. No.60/462,750, attorney docket no. 25791.193, filed on Apr. 14, 2003, (101)U.S. provisional patent application Ser. No. 60/436,106, attorney docketno. 25791.200, filed on Dec. 23, 2002, (102) U.S. provisional patentapplication Ser. No. 60/442,942, attorney docket no. 25791.213, filed onJan. 27, 2003, (103) U.S. provisional patent application Ser. No.60/442,938, attorney docket no. 25791.225, filed on Jan. 27, 2003, (104)U.S. provisional patent application Ser. No. 60/418,687, attorney docketno. 25791.228, filed on Apr. 18, 2003, (105) U.S. provisional patentapplication Ser. No. 60/454,896, attorney docket no. 25791.236, filed onMar. 14, 2003, (106) U.S. provisional patent application Ser. No.60/450,504, attorney docket no. 25791.238, filed on Feb. 26, 2003, (107)U.S. provisional patent application Ser. No. 60/451,152, attorney docketno. 25791.239, filed on Mar. 9, 2003, (108) U.S. provisional patentapplication Ser. No. 60/455,124, attorney docket no. 25791.241, filed onMar. 17, 2003, (109) U.S. provisional patent application Ser. No.60/453,678, attorney docket no. 25791.253, filed on Mar. 11, 2003, (110)U.S. patent application Ser. No. 10/421,682, attorney docket no.25791.256, filed on Apr. 23, 2003, which is a continuation of U.S.patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02,filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903 which issued Nov.4, 2003), which claims priority from provisional application 60/124,042,filed on Mar. 11, 1999, (111) U.S. provisional patent application Ser.No. 60/457,965, attorney docket no. 25791.260, filed on Mar. 27, 2003,(112) U.S. provisional patent application Ser. No. 60/455,718, attorneydocket no. 25791.262, filed on Mar. 18, 2003, (113) U.S. Pat. No.6,550,821, which was filed as patent application Ser. No. 09/811,734,filed on Mar. 19, 2001, (114) U.S. patent application Ser. No.10/436,467, attorney docket no. 25791.268, filed on May 12, 2003, whichis a continuation of U.S. Pat. No. 6,604,763, which was filed asapplication Ser. No. 09/559,122, attorney docket no. 25791.23.02, filedon Apr. 26, 2000, which claims priority from provisional application60/131,106, filed on Apr. 26, 1999, (115) U.S. provisional patentapplication Ser. No. 60/459,776, attorney docket no. 25791.270, filed onApr. 2, 2003, (116) U.S. provisional patent application Ser. No.60/461,094, attorney docket no. 25791.272, filed on Apr. 8, 2003, (117)U.S. provisional patent application Ser. No. 60/461,038, attorney docketno. 25791.273, filed on Apr. 7, 2003, (118) U.S. provisional patentapplication Ser. No. 60/463,586, attorney docket no. 25791.277, filed onApr. 17, 2003, (119) U.S. provisional patent application Ser. No.60/472,240, attorney docket no. 25791.286, filed on May 20, 2003, (120)U.S. patent application Ser. No. 10/619,285, attorney docket no.25791.292, filed on Jul. 14, 2003, which is a continuation-in-part ofU.S. utility patent application Ser. No. 09/969,922, attorney docket no.25791.69, filed on Oct. 3, 2001, (now U.S. Pat. No. 6,634,431 whichissued Oct. 21, 2003), which is a continuation-in-part application ofU.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser.No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15,1999, which claims priority from provisional application 60/108,558,filed on Nov. 16, 1998, (121) U.S. utility patent application Ser. No.10/418,688, attorney docket no. 25791.257, which was filed on Apr. 18,2003, as a division of U.S. utility patent application Ser. No.09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,(now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003), which claimspriority from provisional application 60/124,042, filed on Mar. 11,1999; (122) PCT patent application serial no. PCT/US2004/06246, attorneydocket no. 25791.238.02, filed on Feb. 26, 2004; (123) PCT patentapplication serial number PCT/US2004/08170, attorney docket number25791.40.02, filed on Mar. 15, 2004; (124) PCT patent application serialnumber PCT/US2004/08171, attorney docket number 25791.236.02, filed onMar. 15, 2004; (125) PCT patent application serial numberPCT/US2004/08073, attorney docket number 25791.262.02, filed on Mar. 18,2004; (126) PCT patent application serial number PCT/US2004/07711,attorney docket number 25791.253.02, filed on Mar. 11, 2004; (127) PCTpatent application serial number PCT/US2004/029025, attorney docketnumber 25791.260.02, filed on Mar. 26, 2004; (128) PCT patentapplication serial number PCT/US2004/010317, attorney docket number25791.270.02, filed on Apr. 2, 2004; (129) PCT patent application serialnumber PCT/US2004/010712, attorney docket number 25791.272.02, filed onApr. 6, 2004; (130) PCT patent application serial numberPCT/US2004/010762, attorney docket number 25791.273.02, filed on Apr. 6,2004; (131) PCT patent application serial number PCT/US2004/011973,attorney docket number 25791.277.02, filed on Apr. 15, 2004; (132) U.S.provisional patent application Ser. No. 60/495,056, attorney docketnumber 25791.301, filed on Aug. 14, 2003; (133) U.S. provisional patentapplication Ser. No. 60/600,679, attorney docket number 25791.194, filedon Aug. 11, 2004; (134) PCT patent application serial numberPCT/US2005/027318, attorney docket number 25791.329.02, filed on Jul.29, 2005; (135) PCT patent application serial number PCT/US2005/028936,attorney docket number 25791.338.02, filed on Aug. 12, 2005; (136) PCTpatent application serial number PCT/US2005/028669, attorney docketnumber 25791.194.02, filed on Aug. 11, 2005; (137) PCT patentapplication serial number PCT/US2005/028453, attorney docket number25791.371, filed on Aug. 11, 2005; (138) PCT patent application serialnumber PCT/US2005/028641, attorney docket number 25791.372, filed onAug. 11, 2005; (139) PCT patent application serial numberPCT/US2005/028819, attorney docket number 25791.373, filed on Aug. 11,2005; (140) PCT patent application serial number PCT/US2005/028446,attorney docket number 25791.374, filed on Aug. 11, 2005; (141) PCTpatent application serial number PCT/US2005/028642, attorney docketnumber 25791.375, filed on Aug. 11, 2005; (142) PCT patent applicationserial number PCT/US2005/028451, attorney docket number 25791.376, filedon Aug. 11, 2005, and (143). PCT patent application serial numberPCT/US2005/028473, attorney docket number 25791.377, filed on Aug. 11,2005, (144) U.S. utility patent application Ser. No. 10/546,082,attorney docket number 25791.378, filed on Aug. 16, 2005, (145) U.S.utility patent application Ser. No. 10/546,076, attorney docket number25791.379, filed on Aug. 16, 2005, (146) U.S. utility patent applicationSer. No. 10/545,936, attorney docket number 25791.380, filed on Aug. 16,2005, (147) U.S. utility patent application Ser. No. 10/546,079,attorney docket number 25791.381, filed on Aug. 16, 2005 (148) U.S.utility patent application Ser. No. 10/545,941, attorney docket number25791.382, filed on Aug. 16, 2005, (149) U.S. utility patent applicationSer. No. 546078, attorney docket number 25791.383, filed on Aug. 16,2005, filed on Aug. 11, 2005., (150) U.S. utility patent applicationSer. No. 10/545,941, attorney docket number 25791.185.05, filed on Aug.16, 2005, (151) U.S. utility patent application Ser. No. 11/249,967,attorney docket number 25791.384, filed on Oct. 13, 2005, (152) U.S.provisional patent application Ser. No. 60/734,302, attorney docketnumber 25791.24, filed on Nov. 7, 2005, (153) U.S. provisional patentapplication Ser. No. 60/725,181, attorney docket number 25791.184, filedon Oct. 11, 2005, (154) PCT patent application serial numberPCT/US2005/023391, attorney docket number 25791.299.02 filed Jun. 29,2005 which claims priority from U.S. provisional patent application Ser.No. 60/585,370, attorney docket number 25791.299, filed on Jul. 2, 2004,(155) U.S. provisional patent application Ser. No. 60/721,579, attorneydocket number 25791.327, filed on Sep. 28, 2005, (156) U.S. provisionalpatent application Ser. No. 60/717,391, attorney docket number25791.214, filed on Sep. 15, 2005, (157) U.S. provisional patentapplication Ser. No. 60/702,935, attorney docket number 25791.133, filedon Jul. 27, 2005, (158) U.S. provisional patent application Ser. No.60/663,913, attorney docket number 25791.32, filed on Mar. 21, 2005,(159) U.S. provisional patent application Ser. No. 60/652,564, attorneydocket number 25791.348, filed on Feb. 14, 2005, (160) U.S. provisionalpatent application Ser. No. 60/645,840, attorney docket number25791.324, filed on Jan. 21, 2005, (161) PCT patent application serialnumber PCT/US2005/______, attorney docket number 25791.326.02, filed onNov. 29, 2005 which claims priority from U.S. provisional patentapplication Ser. No. 60/631,703, attorney docket number 25791.326, filedon Nov. 30, 2004, (162) U.S. provisional patent application Ser. No.______, attorney docket number 25791.339, filed on Dec. 22, 2005, (163)U.S. National Stage application Ser. No. 10/548,934, attorney docket no.25791.253.05, filed on Sep. 12, 2005; (164) U.S. National Stageapplication Ser. No. 10/549,410, attorney docket no. 25791.262.05, filedon Sep. 13, 2005; (165) U.S. Provisional Patent Application No.60/717,391, attorney docket no. 25791.214 filed on Sep. 15, 2005; (166)U.S. National Stage application Ser. No. 10/550,906, attorney docket no.25791.260.06, filed on Sep. 27, 2005; (167) U.S. National Stageapplication Ser. No. 10/551,880, attorney docket no. 25791.270.06, filedon Sep. 30, 2005; (168) U.S. National Stage application Ser. No.10/552,253, attorney docket no. 25791.273.06, filed on Oct. 4, 2005;(169) U.S. National Stage application Ser. No. 10/552,790, attorneydocket no. 25791.272.06, filed on Oct. 11, 2005; (170) U.S. ProvisionalPatent Application No. 60/725,181, attorney docket no. 25791.184 filedon Oct. 11, 2005; (171) U.S. National Stage application Ser. No.10/553,094, attorney docket no. 25791.193.03, filed on Oct. 13, 2005;(172) U.S. National Stage application Ser. No. 10/553,566, attorneydocket no. 25791.277.06, filed on Oct. 17, 2005; (173) PCT PatentApplication No. PCT/US2006/______, attorney docket no. 25791.324.02filed on Jan. 20, 2006, and (174) PCT Patent Application No.PCT/US2006/______, attorney docket no. 25791.348.02 filed on Feb. 9,2006; (175) U.S. Utility patent application Ser. No. ______, attorneydocket no. 25791.386, filed on Feb. 17, 2006, (176) U.S. National Stageapplication Ser. No. ______, attorney docket no. 25791.301.06, filed on______, (177) U.S. National Stage application Ser. No. ______, attorneydocket no. 25791.137.04, filed on ______, (178) U.S. National Stageapplication Ser. No. ______, attorney docket no. 25791.215.06, (179)U.S. National State patent application Ser. No. ______, attorney docketno. 25791.305.05, filed on ______; (180) U.S. National State patentapplication Ser. No. ______, attorney docket no. 25791.306.04, filed on______; (181) U.S. National State patent application Ser. No. ______,attorney docket no. 25791.307.04, filed on ______; and (182) U.S.National State patent application Ser. No. ______, attorney docket no.25791.308.07, filed on ______, the disclosures of which are incorporatedherein by reference.

BACKGROUND OF THE INVENTION

This invention relates generally to oil and gas exploration, and inparticular to forming and repairing wellbore casings to facilitate oiland gas exploration.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary cross sectional view of an exemplary embodimentof an expandable tubular member positioned within a preexistingstructure.

FIG. 2 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 1 after positioning an expansion device within theexpandable tubular member.

FIG. 3 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 2 after operating the expansion device within theexpandable tubular member to radially expand and plastically deform aportion of the expandable tubular member.

FIG. 4 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 3 after operating the expansion device within theexpandable tubular member to radially expand and plastically deformanother portion of the expandable tubular member.

FIG. 5 is a graphical illustration of exemplary embodiments of thestress/strain curves for several portions of the expandable tubularmember of FIGS. 1-4.

FIG. 6 is a graphical illustration of the an exemplary embodiment of theyield strength vs. ductility curve for at least a portion of theexpandable tubular member of FIGS. 1-4.

FIG. 7 is a fragmentary cross sectional illustration of an embodiment ofa series of overlapping expandable tubular members.

FIG. 8 is a fragmentary cross sectional view of an exemplary embodimentof an expandable tubular member positioned within a preexistingstructure.

FIG. 9 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 8 after positioning an expansion device within theexpandable tubular member.

FIG. 10 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 9 after operating the expansion device within theexpandable tubular member to radially expand and plastically deform aportion of the expandable tubular member.

FIG. 11 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 10 after operating the expansion device within theexpandable tubular member to radially expand and plastically deformanother portion of the expandable tubular member.

FIG. 12 is a graphical illustration of exemplary embodiments of thestress/strain curves for several portions of the expandable tubularmember of FIGS. 8-11.

FIG. 13 is a graphical illustration of an exemplary embodiment of theyield strength vs. ductility curve for at least a portion of theexpandable tubular member of FIGS. 8-11.

FIG. 14 is a fragmentary cross sectional view of an exemplary embodimentof an expandable tubular member positioned within a preexistingstructure.

FIG. 15 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 14 after positioning an expansion device within theexpandable tubular member.

FIG. 16 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 15 after operating the expansion device within theexpandable tubular member to radially expand and plastically deform aportion of the expandable tubular member.

FIG. 17 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 16 after operating the expansion device within theexpandable tubular member to radially expand and plastically deformanother portion of the expandable tubular member.

FIG. 18 is a flow chart illustration of an exemplary embodiment of amethod of processing an expandable tubular member.

FIG. 19 is a graphical illustration of the an exemplary embodiment ofthe yield strength vs. ductility curve for at least a portion of theexpandable tubular member during the operation of the method of FIG. 18.

FIG. 20 is a graphical illustration of stress/strain curves for anexemplary embodiment of an expandable tubular member.

FIG. 21 is a graphical illustration of stress/strain curves for anexemplary embodiment of an expandable tubular member.

FIG. 22 is a fragmentary cross-sectional view illustrating an embodimentof the radial expansion and plastic deformation of a portion of a firsttubular member having an internally threaded connection at an endportion, an embodiment of a tubular sleeve supported by the end portionof the first tubular member, and a second tubular member having anexternally threaded portion coupled to the internally threaded portionof the first tubular member and engaged by a flange of the sleeve. Thesleeve includes the flange at one end for increasing axial compressionloading.

FIG. 23 is a fragmentary cross-sectional view illustrating an embodimentof the radial expansion and plastic deformation of a portion of a firsttubular member having an internally threaded connection at an endportion, a second tubular member having an externally threaded portioncoupled to the internally threaded portion of the first tubular member,and an embodiment of a tubular sleeve supported by the end portion ofboth tubular members. The sleeve includes flanges at opposite ends forincreasing axial tension loading.

FIG. 24 is a fragmentary cross-sectional illustration of the radialexpansion and plastic deformation of a portion of a first tubular memberhaving an internally threaded connection at an end portion, a secondtubular member having an externally threaded portion coupled to theinternally threaded portion of the first tubular member, and anembodiment of a tubular sleeve supported by the end portion of bothtubular members. The sleeve includes flanges at opposite ends forincreasing axial compression/tension loading.

FIG. 25 is a fragmentary cross-sectional illustration of the radialexpansion and plastic deformation of a portion of a first tubular memberhaving an internally threaded connection at an end portion, a secondtubular member having an externally threaded portion coupled to theinternally threaded portion of the first tubular member, and anembodiment of a tubular sleeve supported by the end portion of bothtubular members. The sleeve includes flanges at opposite ends havingsacrificial material thereon.

FIG. 26 is a fragmentary cross-sectional illustration of the radialexpansion and plastic deformation of a portion of a first tubular memberhaving an internally threaded connection at an end portion, a secondtubular member having an externally threaded portion coupled to theinternally threaded portion of the first tubular member, and anembodiment of a tubular sleeve supported by the end portion of bothtubular members. The sleeve includes a thin walled cylinder ofsacrificial material.

FIG. 27 is a fragmentary cross-sectional illustration of the radialexpansion and plastic deformation of a portion of a first tubular memberhaving an internally threaded connection at an end portion, a secondtubular member having an externally threaded portion coupled to theinternally threaded portion of the first tubular member, and anembodiment of a tubular sleeve supported by the end portion of bothtubular members. The sleeve includes a variable thickness along thelength thereof.

FIG. 28 is a fragmentary cross-sectional illustration of the radialexpansion and plastic deformation of a portion of a first tubular memberhaving an internally threaded connection at an end portion, a secondtubular member having an externally threaded portion coupled to theinternally threaded portion of the first tubular member, and anembodiment of a tubular sleeve supported by the end portion of bothtubular members. The sleeve includes a member coiled onto grooves formedin the sleeve for varying the sleeve thickness.

FIG. 29 is a fragmentary cross-sectional illustration of an exemplaryembodiment of an expandable connection.

FIGS. 30 a-30 c are fragmentary cross-sectional illustrations ofexemplary embodiments of expandable connections.

FIG. 31 is a fragmentary cross-sectional illustration of an exemplaryembodiment of an expandable connection.

FIGS. 32 a and 32 b are fragmentary cross-sectional illustrations of theformation of an exemplary embodiment of an expandable connection.

FIG. 33 is a fragmentary cross-sectional illustration of an exemplaryembodiment of an expandable connection.

FIGS. 34 a, 34 b and 34 c are fragmentary cross-sectional illustrationsof an exemplary embodiment of an expandable connection.

FIG. 35 a is a fragmentary cross-sectional illustration of an exemplaryembodiment of an expandable tubular member.

FIG. 35 b is a graphical illustration of an exemplary embodiment of thevariation in the yield point for the expandable tubular member of FIG.35 a.

FIG. 36 a is a flow chart illustration of an exemplary embodiment of amethod for processing a tubular member.

FIG. 36 b is an illustration of the microstructure of an exemplaryembodiment of a tubular member prior to thermal processing.

FIG. 36 c is an illustration of the microstructure of an exemplaryembodiment of a tubular member after thermal processing.

FIG. 37 a is a flow chart illustration of an exemplary embodiment of amethod for processing a tubular member.

FIG. 37 b is an illustration of the microstructure of an exemplaryembodiment of a tubular member prior to thermal processing.

FIG. 37 c is an illustration of the microstructure of an exemplaryembodiment of a tubular member after thermal processing.

FIG. 38 a is a flow chart illustration of an exemplary embodiment of amethod for processing a tubular member.

FIG. 38 b is an illustration of the microstructure of an exemplaryembodiment of a tubular member prior to thermal processing.

FIG. 38 c is an illustration of the microstructure of an exemplaryembodiment of a tubular member after thermal processing.

FIG. 39 a is a side view illustrating an exemplary embodiment of anexpansion device.

FIG. 39 b is a cross sectional view illustrating an exemplary embodimentof the expansion device of FIG. 39 a in a retracted position.

FIG. 39 c is a perspective view illustrating an exemplary embodiment ofan expansion segment used with the expansion device of FIG. 39 a.

FIG. 39 d is a cross sectional view taken along line 39 d in FIG. 39 billustrating an exemplary embodiment of the expansion device of FIG. 39a.

FIG. 40 a is a side view illustrating an exemplary embodiment of theexpansion device of FIG. 39 a in an expanded position.

FIG. 40 b is a cross sectional view illustrating an exemplary embodimentof the expansion device of FIG. 40 a.

FIG. 40 c is a cross sectional view taken along line 40 c in FIG. 40 billustrating an exemplary embodiment of the expansion device of FIG. 40a.

FIG. 41 is a perspective view illustrating an exemplary embodiment of atubular member.

FIG. 42 a is a cross sectional view illustrating an exemplary embodimentof the expansion device of FIG. 39 b positioned in the tubular member ofFIG. 41.

FIG. 42 b is a cross sectional view illustrating an exemplary embodimentof the expansion device of FIG. 40 b positioned in the tubular member ofFIG. 41.

FIG. 43 a is a side view illustrating an exemplary embodiment of anexpansion device.

FIG. 43 b is a cross sectional view illustrating an exemplary embodimentof the expansion device of FIG. 43 a in a retracted position.

FIG. 43 c is a cross sectional view illustrating an exemplary embodimentof the expansion device of FIG. 43 a in an expanded position.

FIG. 44 a is a cross sectional view illustrating an exemplary embodimentof the expansion device of FIG. 43 b positioned in the tubular member ofFIG. 41.

FIG. 44 b is a cross sectional view illustrating an exemplary embodimentof the expansion device of FIG. 43 c positioned in the tubular member ofFIG. 41.

FIG. 45 a is a cross sectional view illustrating an exemplary embodimentof an expansion device.

FIG. 45 b is a cross sectional view illustrating an exemplary embodimentof the expansion device of FIG. 45 a in an intermediate expandedposition.

FIG. 45 c is a cross sectional view illustrating an exemplary embodimentof the expansion device of FIG. 45 a in an expanded position.

FIG. 46 is a cross sectional view illustrating an exemplary embodimentof an expansion device in the tubular member of FIG. 41.

FIG. 47 a is a cross sectional view illustrating an exemplary embodimentof the expansion device of FIG. 46 in a retracted position.

FIG. 47 b is a cross sectional view illustrating an exemplary embodimentof the expansion device of FIG. 46 in an expanded position.

FIG. 47 c is a cross sectional view illustrating an exemplary embodimentof the expansion device of FIG. 46 being displaced through the tubularmember of FIG. 41.

FIG. 48 is a schematic fragmentary cross-sectional view along a planealong and through the central axis of a tubular member that is tested tofailure with axial opposed forces.

FIG. 49 is a stress-strain curve representing values for stress andstrain that may be plotted for solid specimen sample.

FIG. 50 is a schematically depiction of a stress strain curverepresenting values from an exemplary test on a tubular member.

FIG. 51 is a graphical illustration of an exemplary experimentalembodiment.

FIG. 52 is a graphical illustration of an exemplary experimentalembodiment.

FIG. 53 is a flow chart illustration of an exemplary embodiment of amethod of processing tubular members.

FIG. 54 is a graphical illustration of an exemplary embodiment of amethod of processing tubular members.

FIG. 55 is a graphical illustration of an exemplary embodiment of amethod of processing tubular members.

FIG. 56 is a graphical illustration of an exemplary embodiment of amethod of processing tubular members.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring initially to FIG. 1, an exemplary embodiment of an expandabletubular assembly 10 includes a first expandable tubular member 12coupled to a second expandable tubular member 14. In several exemplaryembodiments, the ends of the first and second expandable tubularmembers, 12 and 14, are coupled using, for example, a conventionalmechanical coupling, a welded connection, a brazed connection, athreaded connection, and/or an interference fit connection. In anexemplary embodiment, the first expandable tubular member 12 has aplastic yield point YP₁, and the second expandable tubular member 14 hasa plastic yield point YP₂. In an exemplary embodiment, the expandabletubular assembly 10 is positioned within a preexisting structure suchas, for example, a wellbore 16 that traverses a subterranean formation18.

As illustrated in FIG. 2, an expansion device 20 may then be positionedwithin the second expandable tubular member 14. In several exemplaryembodiments, the expansion device 20 may include, for example, one ormore of the following conventional expansion devices: a) an expansioncone; b) a rotary expansion device; c) a hydroforming expansion device;d) an impulsive force expansion device; d) any one of the expansiondevices commercially available from, or disclosed in any of thepublished patent applications or issued patents, of WeatherfordInternational, Baker Hughes, Halliburton Energy Services, Shell Oil Co.,Schlumberger, and/or Enventure Global Technology L.L.C. In severalexemplary embodiments, the expansion device 20 is positioned within thesecond expandable tubular member 14 before, during, or after theplacement of the expandable tubular assembly 10 within the preexistingstructure 16.

As illustrated in FIG. 3, the expansion device 20 may then be operatedto radially expand and plastically deform at least a portion of thesecond expandable tubular member 14 to form a bell-shaped section.

As illustrated in FIG. 4, the expansion device 20 may then be operatedto radially expand and plastically deform the remaining portion of thesecond expandable tubular member 14 and at least a portion of the firstexpandable tubular member 12.

In an exemplary embodiment, at least a portion of at least a portion ofat least one of the first and second expandable tubular members, 12 and14, are radially expanded into intimate contact with the interiorsurface of the preexisting structure 16.

In an exemplary embodiment, as illustrated in FIG. 5, the plastic yieldpoint YP₁ is greater than the plastic yield point YP₂. In this manner,in an exemplary embodiment, the amount of power and/or energy requiredto radially expand the second expandable tubular member 14 is less thanthe amount of power and/or energy required to radially expand the firstexpandable tubular member 12.

In an exemplary embodiment, as illustrated in FIG. 6, the firstexpandable tubular member 12 and/or the second expandable tubular member14 have a ductility D_(PE) and a yield strength YS_(PE) prior to radialexpansion and plastic deformation, and a ductility D_(AE) and a yieldstrength YS_(AE) after radial expansion and plastic deformation. In anexemplary embodiment, D_(PE) is greater than D_(AE), and YS_(AE) isgreater than YS_(PE). In this manner, the first expandable tubularmember 12 and/or the second expandable tubular member 14 are transformedduring the radial expansion and plastic deformation process.Furthermore, in this manner, in an exemplary embodiment, the amount ofpower and/or energy required to radially expand each unit length of thefirst and/or second expandable tubular members, 12 and 14, is reduced.Furthermore, because the YS_(AE) is greater than YS_(PE), the collapsestrength of the first expandable tubular member 12 and/or the secondexpandable tubular member 14 is increased after the radial expansion andplastic deformation process.

In an exemplary embodiment, as illustrated in FIG. 7, following thecompletion of the radial expansion and plastic deformation of theexpandable tubular assembly 10 described above with reference to FIGS.1-4, at least a portion of the second expandable tubular member 14 hasan inside diameter that is greater than at least the inside diameter ofthe first expandable tubular member 12. In this manner a bell-shapedsection is formed using at least a portion of the second expandabletubular member 14. Another expandable tubular assembly 22 that includesa first expandable tubular member 24 and a second expandable tubularmember 26 may then be positioned in overlapping relation to the firstexpandable tubular assembly 10 and radially expanded and plasticallydeformed using the methods described above with reference to FIGS. 1-4.Furthermore, following the completion of the radial expansion andplastic deformation of the expandable tubular assembly 20, in anexemplary embodiment, at least a portion of the second expandabletubular member 26 has an inside diameter that is greater than at leastthe inside diameter of the first expandable tubular member 24. In thismanner a bell-shaped section is formed using at least a portion of thesecond expandable tubular member 26. Furthermore, in this manner, amono-diameter tubular assembly is formed that defines an internalpassage 28 having a substantially constant cross-sectional area and/orinside diameter.

Referring to FIG. 8, an exemplary embodiment of an expandable tubularassembly 100 includes a first expandable tubular member 102 coupled to atubular coupling 104. The tubular coupling 104 is coupled to a tubularcoupling 106. The tubular coupling 106 is coupled to a second expandabletubular member 108. In several exemplary embodiments, the tubularcouplings, 104 and 106, provide a tubular coupling assembly for couplingthe first and second expandable tubular members, 102 and 108, togetherthat may include, for example, a conventional mechanical coupling, awelded connection, a brazed connection, a threaded connection, and/or aninterference fit connection. In an exemplary embodiment, the first andsecond expandable tubular members 12 have a plastic yield point YP₁, andthe tubular couplings, 104 and 106, have a plastic yield point YP₂. Inan exemplary embodiment, the expandable tubular assembly 100 ispositioned within a preexisting structure such as, for example, awellbore 110 that traverses a subterranean formation 112.

As illustrated in FIG. 9, an expansion device 114 may then be positionedwithin the second expandable tubular member 108. In several exemplaryembodiments, the expansion device 114 may include, for example, one ormore of the following conventional expansion devices: a) an expansioncone; b) a rotary expansion device; c) a hydroforming expansion device;d) an impulsive force expansion device; d) any one of the expansiondevices commercially available from, or disclosed in any of thepublished patent applications or issued patents, of WeatherfordInternational, Baker Hughes, Halliburton Energy Services, Shell Oil Co.,Schlumberger, and/or Enventure Global Technology L.L.C. In severalexemplary embodiments, the expansion device 114 is positioned within thesecond expandable tubular member 108 before, during, or after theplacement of the expandable tubular assembly 100 within the preexistingstructure 110.

As illustrated in FIG. 10, the expansion device 114 may then be operatedto radially expand and plastically deform at least a portion of thesecond expandable tubular member 108 to form a bell-shaped section.

As illustrated in FIG. 11, the expansion device 114 may then be operatedto radially expand and plastically deform the remaining portion of thesecond expandable tubular member 108, the tubular couplings, 104 and106, and at least a portion of the first expandable tubular member 102.

In an exemplary embodiment, at least a portion of at least a portion ofat least one of the first and second expandable tubular members, 102 and108, are radially expanded into intimate contact with the interiorsurface of the preexisting structure 110.

In an exemplary embodiment, as illustrated in FIG. 12, the plastic yieldpoint YP₁ is less than the plastic yield point YP₂. In this manner, inan exemplary embodiment, the amount of power and/or energy required toradially expand each unit length of the first and second expandabletubular members, 102 and 108, is less than the amount of power and/orenergy required to radially expand each unit length of the tubularcouplings, 104 and 106.

In an exemplary embodiment, as illustrated in FIG. 13, the firstexpandable tubular member 12 and/or the second expandable tubular member14 have a ductility D_(PE) and a yield strength YS_(PE) prior to radialexpansion and plastic deformation, and a ductility D_(AE) and a yieldstrength YS_(AE) after radial expansion and plastic deformation. In anexemplary embodiment, D_(PE) is greater than D_(AE), and YS_(AE) isgreater than YS_(PE). In this manner, the first expandable tubularmember 12 and/or the second expandable tubular member 14 are transformedduring the radial expansion and plastic deformation process.Furthermore, in this manner, in an exemplary embodiment, the amount ofpower and/or energy required to radially expand each unit length of thefirst and/or second expandable tubular members, 12 and 14, is reduced.Furthermore, because the YS_(AE) is greater than YS_(PE), the collapsestrength of the first expandable tubular member 12 and/or the secondexpandable tubular member 14 is increased after the radial expansion andplastic deformation process.

Referring to FIG. 14, an exemplary embodiment of an expandable tubularassembly 200 includes a first expandable tubular member 202 coupled to asecond expandable tubular member 204 that defines radial openings 204 a,204 b, 204 c, and 204 d. In several exemplary embodiments, the ends ofthe first and second expandable tubular members, 202 and 204, arecoupled using, for example, a conventional mechanical coupling, a weldedconnection, a brazed connection, a threaded connection, and/or aninterference fit connection. In an exemplary embodiment, one or more ofthe radial openings, 204 a, 204 b, 204 c, and 204 d, have circular,oval, square, and/or irregular cross sections and/or include portionsthat extend to and interrupt either end of the second expandable tubularmember 204. In an exemplary embodiment, the expandable tubular assembly200 is positioned within a preexisting structure such as, for example, awellbore 206 that traverses a subterranean formation 208.

As illustrated in FIG. 15, an expansion device 210 may then bepositioned within the second expandable tubular member 204. In severalexemplary embodiments, the expansion device 210 may include, forexample, one or more of the following conventional expansion devices: a)an expansion cone; b) a rotary expansion device; c) a hydroformingexpansion device; d) an impulsive force expansion device; d) any one ofthe expansion devices commercially available from, or disclosed in anyof the published patent applications or issued patents, of WeatherfordInternational, Baker Hughes, Halliburton Energy Services, Shell Oil Co.,Schlumberger, and/or Enventure Global Technology L.L.C. In severalexemplary embodiments, the expansion device 210 is positioned within thesecond expandable tubular member 204 before, during, or after theplacement of the expandable tubular assembly 200 within the preexistingstructure 206.

As illustrated in FIG. 16, the expansion device 210 may then be operatedto radially expand and plastically deform at least a portion of thesecond expandable tubular member 204 to form a bell-shaped section.

As illustrated in FIG. 16, the expansion device 20 may then be operatedto radially expand and plastically deform the remaining portion of thesecond expandable tubular member 204 and at least a portion of the firstexpandable tubular member 202.

In an exemplary embodiment, the anisotropy ratio AR for the first andsecond expandable tubular members is defined by the following equation:AR=In(WT_(f)/WT_(o))/In(D_(f)/D_(o));

where AR=anisotropy ratio;

where WT_(f)=final wall thickness of the expandable tubular memberfollowing the radial expansion and plastic deformation of the expandabletubular member;

where WT_(i)=initial wall thickness of the expandable tubular memberprior to the radial expansion and plastic deformation of the expandabletubular member;

where D_(f)=final inside diameter of the expandable tubular memberfollowing the radial expansion and plastic deformation of the expandabletubular member; and

where D_(i)=initial inside diameter of the expandable tubular memberprior to the radial expansion and plastic deformation of the expandabletubular member.

In an exemplary embodiment, the anisotropy ratio AR for the first and/orsecond expandable tubular members, 204 and 204, is greater than 1.

In an exemplary experimental embodiment, the second expandable tubularmember 204 had an anisotropy ratio AR greater than 1, and the radialexpansion and plastic deformation of the second expandable tubularmember did not result in any of the openings, 204 a, 204 b, 204 c, and204 d, splitting or otherwise fracturing the remaining portions of thesecond expandable tubular member. This was an unexpected result.

Referring to FIG. 18, in an exemplary embodiment, one or more of theexpandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202and/or 204 are processed using a method 300 in which a tubular member inan initial state is thermo-mechanically processed in step 302. In anexemplary embodiment, the thermo-mechanical processing 302 includes oneor more heat treating and/or mechanical forming processes. As a result,of the thermo-mechanical processing 302, the tubular member istransformed to an intermediate state. The tubular member is then furtherthermo-mechanically processed in step 304. In an exemplary embodiment,the thermo-mechanical processing 304 includes one or more heat treatingand/or mechanical forming processes. As a result, of thethermo-mechanical processing 304, the tubular member is transformed to afinal state.

In an exemplary embodiment, as illustrated in FIG. 19, during theoperation of the method 300, the tubular member has a ductility D_(PE)and a yield strength YS_(PE) prior to the final thermo-mechanicalprocessing in step 304, and a ductility D_(AE) and a yield strengthYS_(AE) after final thermo-mechanical processing. In an exemplaryembodiment, D_(PE) is greater than D_(AE), and YS_(AE) is greater thanYS_(PE). In this manner, the amount of energy and/or power required totransform the tubular member, using mechanical forming processes, duringthe final thermo-mechanical processing in step 304 is reduced.Furthermore, in this manner, because the YS_(AE) is greater thanYS_(PE), the collapse strength of the tubular member is increased afterthe final thermo-mechanical processing in step 304.

In an exemplary embodiment, one or more of the expandable tubularmembers, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, have thefollowing characteristics: Characteristic Value Tensile Strength 60 to120 ksi Yield Strength 50 to 100 ksi Y/T Ratio Maximum of 50/85%Elongation During Radial Expansion and Minimum of 35% PlasticDeformation Width Reduction During Radial Expansion Minimum of 40% andPlastic Deformation Wall Thickness Reduction During Radial Minimum of30% Expansion and Plastic Deformation Anisotropy Minimum of 1.5 MinimumAbsorbed Energy at −4 80 ft-lb F. (−20 C.) in the Longitudinal DirectionMinimum Absorbed Energy at −4 60 ft-lb F. (−20 C.) in the TransverseDirection Minimum Absorbed Energy at −4 60 ft-lb F. (−20 C.) TransverseTo A Weld Area Flare Expansion Testing Minimum of 75% Without A FailureIncrease in Yield Strength Due To Greater than 5.4% Radial Expansion andPlastic Deformation

In an exemplary embodiment, one or more of the expandable tubularmembers, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, arecharacterized by an expandability coefficient f:

-   -   i. f=r×n    -   ii. where f=expandability coefficient;        -   1. r=anisotropy coefficient; and        -   2. n=strain hardening exponent.

In an exemplary embodiment, the anisotropy coefficient for one or moreof the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108,202 and/or 204 is greater than 1. In an exemplary embodiment, the strainhardening exponent for one or more of the expandable tubular members,12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is greater than 0.12.In an exemplary embodiment, the expandability coefficient for one ormore of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106,108, 202 and/or 204 is greater than 0.12.

In an exemplary embodiment, a tubular member having a higherexpandability coefficient requires less power and/or energy to radiallyexpand and plastically deform each unit length than a tubular memberhaving a lower expandability coefficient. In an exemplary embodiment, atubular member having a higher expandability coefficient requires lesspower and/or energy per unit length to radially expand and plasticallydeform than a tubular member having a lower expandability coefficient.

In several exemplary experimental embodiments, one or more of theexpandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202and/or 204, are steel alloys having one of the following compositions:Steel Element and Percentage By Weight Alloy C Mn P S Si Cu Ni Cr A0.065 1.44 0.01 0.002 0.24 0.01 0.01 0.02 B 0.18 1.28 0.017 0.004 0.290.01 0.01 0.03 C 0.08 0.82 0.006 0.003 0.30 0.16 0.05 0.05 D 0.02 1.310.02 0.001 0.45 — 9.1 18.7

In exemplary experimental embodiment, as illustrated in FIG. 20, asample of an expandable tubular member composed of Alloy A exhibited ayield point before radial expansion and plastic deformation YP_(BE), ayield point after radial expansion and plastic deformation of about 16%YP_(AE16%), and a yield point after radial expansion and plasticdeformation of about 24% YP_(AE24%). In an exemplary experimentalembodiment, YP_(AE24%)>YP_(AE16%)>YP_(BE). Furthermore, in an exemplaryexperimental embodiment, the ductility of the sample of the expandabletubular member composed of Alloy A also exhibited a higher ductilityprior to radial expansion and plastic deformation than after radialexpansion and plastic deformation. These were unexpected results.

In an exemplary experimental embodiment, a sample of an expandabletubular member composed of Alloy A exhibited the following tensilecharacteristics before and after radial expansion and plasticdeformation: Width Wall Yield Elonga- Reduc- Thickness Point Yield tiontion Reduction Aniso- ksi Ratio % % % tropy Before 46.9 0.69 53 −52 550.93 Radial Expansion and Plastic Deformation After 16% 65.9 0.83 17 4251 0.78 Radial Expansion After 24% 68.5 0.83 5 44 54 0.76 RadialExpansion % Increase 40% for 16% radial expansion 46% for 24% radialexpansion

In exemplary experimental embodiment, as illustrated in FIG. 21, asample of an expandable tubular member composed of Alloy B exhibited ayield point before radial expansion and plastic deformation YP_(BE), ayield point after radial expansion and plastic deformation of about 16%YP_(AE16%), and a yield point after radial expansion and plasticdeformation of about 24% YP_(AE24%). In an exemplary embodiment,YP_(AE24%)>YP_(AE16%)>YP_(BE). Furthermore, in an exemplary experimentalembodiment, the ductility of the sample of the expandable tubular membercomposed of Alloy B also exhibited a higher ductility prior to radialexpansion and plastic deformation than after radial expansion andplastic deformation. These were unexpected results.

In an exemplary experimental embodiment, a sample of an expandabletubular member composed of Alloy B exhibited the following tensilecharacteristics before and after radial expansion and plasticdeformation: Width Wall Yield Elonga- Reduc- Thickness Point Yield tiontion Reduction Aniso- ksi Ratio % % % tropy Before 57.8 0.71 44 43 460.93 Radial Expansion and Plastic Deformation After 16% 74.4 0.84 16 3842 0.87 Radial Expansion After 24% 79.8 0.86 20 36 42 0.81 RadialExpansion % Increase 28.7% increase for 16% radial expansion 38%increase for 24% radial expansion

In an exemplary experimental embodiment, samples of expandable tubularscomposed of Alloys A, B, C, and D exhibited the following tensilecharacteristics prior to radial expansion and plastic deformation:Absorbed Steel Yield Yield Elongation Aniso- Energy Expandability Alloyksi Ratio % tropy ft-lb Coefficient A 47.6 0.71 44 1.48 145 B 57.8 0.7144 1.04 62.2 C 61.7 0.80 39 1.92 268 D 48 0.55 56 1.34 —

In an exemplary embodiment, one or more of the expandable tubularmembers, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 have astrain hardening exponent greater than 0.12, and a yield ratio is lessthan 0.85.

In an exemplary embodiment, the carbon equivalent C_(e), for tubularmembers having a carbon content (by weight percentage) less than orequal to 0.12%, is given by the following expression:C_(e)=C+Mn/6+(Cr+Mo+V+Ti+Nb)/5+(Ni+Cu)/15

where C_(e)=carbon equivalent value;

a. C=carbon percentage by weight;

b. Mn=manganese percentage by weight;

c. Cr=chromium percentage by weight;

d. Mo=molybdenum percentage by weight;

e. V=vanadium percentage by weight;

f. Ti=titanium percentage by weight;

g. Nb=niobium percentage by weight;

h. Ni=nickel percentage by weight; and

i. Cu=copper percentage by weight.

In an exemplary embodiment, the carbon equivalent value C_(e), fortubular members having a carbon content less than or equal to 0.12% (byweight), for one or more of the expandable tubular members, 12, 14, 24,26, 102, 104, 106, 108, 202 and/or 204 is less than 0.21.

In an exemplary embodiment, the carbon equivalent C_(e), for tubularmembers having more than 0.12% carbon content (by weight), is given bythe following expression:C_(e)=C+Si/30+(Mn+Cu+Cr)/20+Ni/60+Mo/15+V/10+5*B

-   -   where C_(e)=carbon equivalent value;

a. C=carbon percentage by weight;

b. Si=silicon percentage by weight;

c. Mn=manganese percentage by weight;

d. Cu=copper percentage by weight;

e. Cr=chromium percentage by weight;

f. Ni=nickel percentage by weight;

g. Mo=molybdenum percentage by weight;

h. V=vanadium percentage by weight; and

i. B=boron percentage by weight.

In an exemplary embodiment, the carbon equivalent value C_(e), fortubular members having greater than 0.12% carbon content (by weight),for one or more of the expandable tubular members, 12, 14, 24, 26, 102,104, 106, 108, 202 and/or 204 is less than 0.36.

Referring to FIG. 22 in an exemplary embodiment, a first tubular member2210 includes an internally threaded connection 2212 at an end portion2214. A first end of a tubular sleeve 2216 that includes an internalflange 2218 having a tapered portion 2220, and a second end thatincludes a tapered portion 2222, is then mounted upon and receives theend portion 2214 of the first tubular member 2210. In an exemplaryembodiment, the end portion 2214 of the first tubular member 2210 abutsone side of the internal flange 2218 of the tubular sleeve 2216, and theinternal diameter of the internal flange 2218 of the tubular sleeve 2216is substantially equal to or greater than the maximum internal diameterof the internally threaded connection 2212 of the end portion 2214 ofthe first tubular member 2210. An externally threaded connection 2224 ofan end portion 2226 of a second tubular member 2228 having an annularrecess 2230 is then positioned within the tubular sleeve 2216 andthreadably coupled to the internally threaded connection 2212 of the endportion 2214 of the first tubular member 2210. In an exemplaryembodiment, the internal flange 2218 of the tubular sleeve 2216 mateswith and is received within the annular recess 2230 of the end portion2226 of the second tubular member 2228. Thus, the tubular sleeve 2216 iscoupled to and surrounds the external surfaces of the first and secondtubular members, 2210 and 2228.

The internally threaded connection 2212 of the end portion 2214 of thefirst tubular member 2210 is a box connection, and the externallythreaded connection 2224 of the end portion 2226 of the second tubularmember 2228 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 2216 is at least approximately0.020″ greater than the outside diameters of the first and secondtubular members, 2210 and 2228. In this manner, during the threadedcoupling of the first and second tubular members, 2210 and 2228, fluidicmaterials within the first and second tubular members may be vented fromthe tubular members.

As illustrated in FIG. 22, the first and second tubular members, 2210and 2228, and the tubular sleeve 2216 may be positioned within anotherstructure 2232 such as, for example, a cased or uncased wellbore, andradially expanded and plastically deformed, for example, by displacingand/or rotating a conventional expansion device 2234 within and/orthrough the interiors of the first and second tubular members. Thetapered portions, 2220 and 2222, of the tubular sleeve 2216 facilitatethe insertion and movement of the first and second tubular memberswithin and through the structure 2232, and the movement of the expansiondevice 2234 through the interiors of the first and second tubularmembers, 2210 and 2228, may be, for example, from top to bottom or frombottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members, 2210 and 2228, the tubular sleeve 2216 is alsoradially expanded and plastically deformed. As a result, the tubularsleeve 2216 may be maintained in circumferential tension and the endportions, 2214 and 2226, of the first and second tubular members, 2210and 2228, may be maintained in circumferential compression.

Sleeve 2216 increases the axial compression loading of the connectionbetween tubular members 2210 and 2228 before and after expansion by theexpansion device 2234. Sleeve 2216 may, for example, be secured totubular members 2210 and 2228 by a heat shrink fit.

In several alternative embodiments, the first and second tubularmembers, 2210 and 2228, are radially expanded and plastically deformedusing other conventional methods for radially expanding and plasticallydeforming tubular members such as, for example, internal pressurization,hydroforming, and/or roller expansion devices and/or any one orcombination of the conventional commercially available expansionproducts and services available from Baker Hughes, WeatherfordInternational, and/or Enventure Global Technology L.L.C.

The use of the tubular sleeve 2216 during (a) the coupling of the firsttubular member 2210 to the second tubular member 2228, (b) the placementof the first and second tubular members in the structure 2232, and (c)the radial expansion and plastic deformation of the first and secondtubular members provides a number of significant benefits. For example,the tubular sleeve 2216 protects the exterior surfaces of the endportions, 2214 and 2226, of the first and second tubular members, 2210and 2228, during handling and insertion of the tubular members withinthe structure 2232. In this manner, damage to the exterior surfaces ofthe end portions, 2214 and 2226, of the first and second tubularmembers, 2210 and 2228, is avoided that could otherwise result in stressconcentrations that could cause a catastrophic failure during subsequentradial expansion operations. Furthermore, the tubular sleeve 2216provides an alignment guide that facilitates the insertion and threadedcoupling of the second tubular member 2228 to the first tubular member2210. In this manner, misalignment that could result in damage to thethreaded connections, 2212 and 2224, of the first and second tubularmembers, 2210 and 2228, may be avoided. In addition, during the relativerotation of the second tubular member with respect to the first tubularmember, required during the threaded coupling of the first and secondtubular members, the tubular sleeve 2216 provides an indication of towhat degree the first and second tubular members are threadably coupled.For example, if the tubular sleeve 2216 can be easily rotated, thatwould indicate that the first and second tubular members, 2210 and 2228,are not fully threadably coupled and in intimate contact with theinternal flange 2218 of the tubular sleeve. Furthermore, the tubularsleeve 2216 may prevent crack propagation during the radial expansionand plastic deformation of the first and second tubular members, 2210and 2228. In this manner, failure modes such as, for example,longitudinal cracks in the end portions, 2214 and 2226, of the first andsecond tubular members may be limited in severity or eliminated alltogether. In addition, after completing the radial expansion and plasticdeformation of the first and second tubular members, 2210 and 2228, thetubular sleeve 2216 may provide a fluid tight metal-to-metal sealbetween interior surface of the tubular sleeve 2216 and the exteriorsurfaces of the end portions, 2214 and 2226, of the first and secondtubular members. In this manner, fluidic materials are prevented frompassing through the threaded connections, 2212 and 2224, of the firstand second tubular members, 2210 and 2228, into the annulus between thefirst and second tubular members and the structure 2232. Furthermore,because, following the radial expansion and plastic deformation of thefirst and second tubular members, 2210 and 2228, the tubular sleeve 2216may be maintained in circumferential tension and the end portions, 2214and 2226, of the first and second tubular members, 2210 and 2228, may bemaintained in circumferential compression, axial loads and/or torqueloads may be transmitted through the tubular sleeve.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 2210 and 2228, and the tubular sleeve 2216 haveone or more of the material properties of one or more of the tubularmembers 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 23, in an exemplary embodiment, a first tubular member210 includes an internally threaded connection 2312 at an end portion2314. A first end of a tubular sleeve 2316 includes an internal flange2318 and a tapered portion 2320. A second end of the sleeve 2316includes an internal flange 2321 and a tapered portion 2322. Anexternally threaded connection 2324 of an end portion 2326 of a secondtubular member 2328 having an annular recess 2330, is then positionedwithin the tubular sleeve 2316 and threadably coupled to the internallythreaded connection 2312 of the end portion 2314 of the first tubularmember 2310. The internal flange 2318 of the sleeve 2316 mates with andis received within the annular recess 2330.

The first tubular member 2310 includes a recess 2331. The internalflange 2321 mates with and is received within the annular recess 2331.Thus, the sleeve 2316 is coupled to and surrounds the external surfacesof the first and second tubular members 2310 and 2328.

The internally threaded connection 2312 of the end portion 2314 of thefirst tubular member 2310 is a box connection, and the externallythreaded connection 2324 of the end portion 2326 of the second tubularmember 2328 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 2316 is at least approximately0.020″ greater than the outside diameters of the first and secondtubular members 2310 and 2328. In this manner, during the threadedcoupling of the first and second tubular members 2310 and 2328, fluidicmaterials within the first and second tubular members may be vented fromthe tubular members.

As illustrated in FIG. 23, the first and second tubular members 2310 and2328, and the tubular sleeve 2316 may then be positioned within anotherstructure 2332 such as, for example, a wellbore, and radially expandedand plastically deformed, for example, by displacing and/or rotating anexpansion device 2334 through and/or within the interiors of the firstand second tubular members. The tapered portions 2320 and 2322, of thetubular sleeve 2316 facilitates the insertion and movement of the firstand second tubular members within and through the structure 2332, andthe displacement of the expansion device 2334 through the interiors ofthe first and second tubular members 2310 and 2328, may be from top tobottom or from bottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members 2310 and 2328, the tubular sleeve 2316 is alsoradially expanded and plastically deformed. In an exemplary embodiment,as a result, the tubular sleeve 2316 may be maintained incircumferential tension and the end portions 2314 and 2326, of the firstand second tubular members 2310 and 2328, may be maintained incircumferential compression.

Sleeve 2316 increases the axial tension loading of the connectionbetween tubular members 2310 and 2328 before and after expansion by theexpansion device 2334. Sleeve 2316 may be secured to tubular members2310 and 2328 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 2310 and 2328, and the tubular sleeve 2316 haveone or more of the material properties of one or more of the tubularmembers 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 24, in an exemplary embodiment, a first tubular member2410 includes an internally threaded connection 2412 at an end portion2414. A first end of a tubular sleeve 2416 includes an internal flange2418 and a tapered portion 2420. A second end of the sleeve 2416includes an internal flange 2421 and a tapered portion 2422. Anexternally threaded connection 2424 of an end portion 2426 of a secondtubular member 2428 having an annular recess 2430, is then positionedwithin the tubular sleeve 2416 and threadably coupled to the internallythreaded connection 2412 of the end portion 2414 of the first tubularmember 2410. The internal flange 2418 of the sleeve 2416 mates with andis received within the annular recess 2430. The first tubular member2410 includes a recess 2431. The internal flange 2421 mates with and isreceived within the annular recess 2431. Thus, the sleeve 2416 iscoupled to and surrounds the external surfaces of the first and secondtubular members 2410 and 2428.

The internally threaded connection 2412 of the end portion 2414 of thefirst tubular member 2410 is a box connection, and the externallythreaded connection 2424 of the end portion 2426 of the second tubularmember 2428 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 2416 is at least approximately0.020″ greater than the outside diameters of the first and secondtubular members 2410 and 2428. In this manner, during the threadedcoupling of the first and second tubular members 2410 and 2428, fluidicmaterials within the first and second tubular members may be vented fromthe tubular members.

As illustrated in FIG. 24, the first and second tubular members 2410 and2428, and the tubular sleeve 2416 may then be positioned within anotherstructure 2432 such as, for example, a wellbore, and radially expandedand plastically deformed, for example, by displacing and/or rotating anexpansion device 2434 through and/or within the interiors of the firstand second tubular members. The tapered portions 2420 and 2422, of thetubular sleeve 2416 facilitate the insertion and movement of the firstand second tubular members within and through the structure 2432, andthe displacement of the expansion device 2434 through the interiors ofthe first and second tubular members, 2410 and 2428, may be from top tobottom or from bottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members, 2410 and 2428, the tubular sleeve 2416 is alsoradially expanded and plastically deformed. In an exemplary embodiment,as a result, the tubular sleeve 2416 may be maintained incircumferential tension and the end portions, 2414 and 2426, of thefirst and second tubular members, 2410 and 2428, may be maintained incircumferential compression.

The sleeve 2416 increases the axial compression and tension loading ofthe connection between tubular members 2410 and 2428 before and afterexpansion by expansion device 2424. Sleeve 2416 may be secured totubular members 2410 and 2428 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 2410 and 2428, and the tubular sleeve 2416 haveone or more of the material properties of one or more of the tubularmembers 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 25, in an exemplary embodiment, a first tubular member2510 includes an internally threaded connection 2512 at an end portion2514. A first end of a tubular sleeve 2516 includes an internal flange2518 and a relief 2520. A second end of the sleeve 2516 includes aninternal flange 2521 and a relief 2522. An externally threadedconnection 2524 of an end portion 2526 of a second tubular member 2528having an annular recess 2530, is then positioned within the tubularsleeve 2516 and threadably coupled to the internally threaded connection2512 of the end portion 2514 of the first tubular member 2510. Theinternal flange 2518 of the sleeve 2516 mates with and is receivedwithin the annular recess 2530. The first tubular member 2510 includes arecess 2531. The internal flange 2521 mates with and is received withinthe annular recess 2531. Thus, the sleeve 2516 is coupled to andsurrounds the external surfaces of the first and second tubular members2510 and 2528.

The internally threaded connection 2512 of the end portion 2514 of thefirst tubular member 2510 is a box connection, and the externallythreaded connection 2524 of the end portion 2526 of the second tubularmember 2528 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 2516 is at least approximately0.020″ greater than the outside diameters of the first and secondtubular members 2510 and 2528. In this manner, during the threadedcoupling of the first and second tubular members 2510 and 2528, fluidicmaterials within the first and second tubular members may be vented fromthe tubular members.

As illustrated in FIG. 25, the first and second tubular members 2510 and2528, and the tubular sleeve 2516 may then be positioned within anotherstructure 2532 such as, for example, a wellbore, and radially expandedand plastically deformed, for example, by displacing and/or rotating anexpansion device 2534 through and/or within the interiors of the firstand second tubular members. The reliefs 2520 and 2522 are each filledwith a sacrificial material 2540 including a tapered surface 2542 and2544, respectively. The material 2540 may be a metal or a synthetic, andis provided to facilitate the insertion and movement of the first andsecond tubular members 2510 and 2528, through the structure 2532. Thedisplacement of the expansion device 2534 through the interiors of thefirst and second tubular members 2510 and 2528, may, for example, befrom top to bottom or from bottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members 2510 and 2528, the tubular sleeve 2516 is alsoradially expanded and plastically deformed. In an exemplary embodiment,as a result, the tubular sleeve 2516 may be maintained incircumferential tension and the end portions 2514 and 2526, of the firstand second tubular members, 2510 and 2528, may be maintained incircumferential compression.

The addition of the sacrificial material 2540, provided on sleeve 2516,avoids stress risers on the sleeve 2516 and the tubular member 2510. Thetapered surfaces 2542 and 2544 are intended to wear or even becomedamaged, thus incurring such wear or damage which would otherwise beborne by sleeve 2516. Sleeve 2516 may be secured to tubular members 2510and 2528 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 2510 and 2528, and the tubular sleeve 2516 haveone or more of the material properties of one or more of the tubularmembers 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 26, in an exemplary embodiment, a first tubular member2610 includes an internally threaded connection 2612 at an end portion2614. A first end of a tubular sleeve 2616 includes an internal flange2618 and a tapered portion 2620. A second end of the sleeve 2616includes an internal flange 2621 and a tapered portion 2622. Anexternally threaded connection 2624 of an end portion 2626 of a secondtubular member 2628 having an annular recess 2630, is then positionedwithin the tubular sleeve 2616 and threadably coupled to the internallythreaded connection 2612 of the end portion 2614 of the first tubularmember 2610. The internal flange 2618 of the sleeve 2616 mates with andis received within the annular recess 2630.

The first tubular member 2610 includes a recess 2631. The internalflange 2621 mates with and is received within the annular recess 2631.Thus, the sleeve 2616 is coupled to and surrounds the external surfacesof the first and second tubular members 2610 and 2628.

The internally threaded connection 2612 of the end portion 2614 of thefirst tubular member 2610 is a box connection, and the externallythreaded connection 2624 of the end portion 2626 of the second tubularmember 2628 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 2616 is at least approximately0.020″ greater than the outside diameters of the first and secondtubular members 2610 and 2628. In this manner, during the threadedcoupling of the first and second tubular members 2610 and 2628, fluidicmaterials within the first and second tubular members may be vented fromthe tubular members.

As illustrated in FIG. 26, the first and second tubular members 2610 and2628, and the tubular sleeve 2616 may then be positioned within anotherstructure 2632 such as, for example, a wellbore, and radially expandedand plastically deformed, for example, by displacing and/or rotating anexpansion device 2634 through and/or within the interiors of the firstand second tubular members. The tapered portions 2620 and 2622, of thetubular sleeve 2616 facilitates the insertion and movement of the firstand second tubular members within and through the structure 2632, andthe displacement of the expansion device 2634 through the interiors ofthe first and second tubular members 2610 and 2628, may, for example, befrom top to bottom or from bottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members 2610 and 2628, the tubular sleeve 2616 is alsoradially expanded and plastically deformed. In an exemplary embodiment,as a result, the tubular sleeve 2616 may be maintained incircumferential tension and the end portions 2614 and 2626, of the firstand second tubular members 2610 and 2628, may be maintained incircumferential compression.

Sleeve 2616 is covered by a thin walled cylinder of sacrificial material2640. Spaces 2623 and 2624, adjacent tapered portions 2620 and 2622,respectively, are also filled with an excess of the sacrificial material2640. The material may be a metal or a synthetic, and is provided tofacilitate the insertion and movement of the first and second tubularmembers 2610 and 2628, through the structure 2632.

The addition of the sacrificial material 2640, provided on sleeve 2616,avoids stress risers on the sleeve 2616 and the tubular member 2610. Theexcess of the sacrificial material 2640 adjacent tapered portions 2620and 2622 are intended to wear or even become damaged, thus incurringsuch wear or damage which would otherwise be borne by sleeve 2616.Sleeve 2616 may be secured to tubular members 2610 and 2628 by a heatshrink fit.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 2610 and 2628, and the tubular sleeve 2616 haveone or more of the material properties of one or more of the tubularmembers 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 27, in an exemplary embodiment, a first tubular member2710 includes an internally threaded connection 2712 at an end portion2714. A first end of a tubular sleeve 2716 includes an internal flange2718 and a tapered portion 2720. A second end of the sleeve 2716includes an internal flange 2721 and a tapered portion 2722. Anexternally threaded connection 2724 of an end portion 2726 of a secondtubular member 2728 having an annular recess 2730, is then positionedwithin the tubular sleeve 2716 and threadably coupled to the internallythreaded connection 2712 of the end portion 2714 of the first tubularmember 2710. The internal flange 2718 of the sleeve 2716 mates with andis received within the annular recess 2730.

The first tubular member 2710 includes a recess 2731. The internalflange 2721 mates with and is received within the annular recess 2731.Thus, the sleeve 2716 is coupled to and surrounds the external surfacesof the first and second tubular members 2710 and 2728.

The internally threaded connection 2712 of the end portion 2714 of thefirst tubular member 2710 is a box connection, and the externallythreaded connection 2724 of the end portion 2726 of the second tubularmember 2728 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 2716 is at least approximately0.020″ greater than the outside diameters of the first and secondtubular members 2710 and 2728. In this manner, during the threadedcoupling of the first and second tubular members 2710 and 2728, fluidicmaterials within the first and second tubular members may be vented fromthe tubular members.

As illustrated in FIG. 27, the first and second tubular members 2710 and2728, and the tubular sleeve 2716 may then be positioned within anotherstructure 2732 such as, for example, a wellbore, and radially expandedand plastically deformed, for example, by displacing and/or rotating anexpansion device 2734 through and/or within the interiors of the firstand second tubular members. The tapered portions 2720 and 2722, of thetubular sleeve 2716 facilitates the insertion and movement of the firstand second tubular members within and through the structure 2732, andthe displacement of the expansion device 2734 through the interiors ofthe first and second tubular members 2710 and 2728, may be from top tobottom or from bottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members 2710 and 2728, the tubular sleeve 2716 is alsoradially expanded and plastically deformed. In an exemplary embodiment,as a result, the tubular sleeve 2716 may be maintained incircumferential tension and the end portions 2714 and 2726, of the firstand second tubular members 2710 and 2728, may be maintained incircumferential compression.

Sleeve 2716 has a variable thickness due to one or more reducedthickness portions 2790 and/or increased thickness portions 2792.

Varying the thickness of sleeve 2716 provides the ability to control orinduce stresses at selected positions along the length of sleeve 2716and the end portions 2724 and 2726. Sleeve 2716 may be secured totubular members 2710 and 2728 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 2710 and 2728, and the tubular sleeve 2716 haveone or more of the material properties of one or more of the tubularmembers 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 28, in an alternative embodiment, instead of varyingthe thickness of sleeve 2716, the same result described above withreference to FIG. 27, may be achieved by adding a member 2740 which maybe coiled onto the grooves 2739 formed in sleeve 2716, thus varying thethickness along the length of sleeve 2716.

Referring to FIG. 29, in an exemplary embodiment, a first tubular member2910 includes an internally threaded connection 2912 and an internalannular recess 2914 at an end portion 2916. A first end of a tubularsleeve 2918 includes an internal flange 2920, and a second end of thesleeve 2916 mates with and receives the end portion 2916 of the firsttubular member 2910. An externally threaded connection 2922 of an endportion 2924 of a second tubular member 2926 having an annular recess2928, is then positioned within the tubular sleeve 2918 and threadablycoupled to the internally threaded connection 2912 of the end portion2916 of the first tubular member 2910. The internal flange 2920 of thesleeve 2918 mates with and is received within the annular recess 2928. Asealing element 2930 is received within the internal annular recess 2914of the end portion 2916 of the first tubular member 2910.

The internally threaded connection 2912 of the end portion 2916 of thefirst tubular member 2910 is a box connection, and the externallythreaded connection 2922 of the end portion 2924 of the second tubularmember 2926 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 2918 is at least approximately0.020″ greater than the outside diameters of the first tubular member2910. In this manner, during the threaded coupling of the first andsecond tubular members 2910 and 2926, fluidic materials within the firstand second tubular members may be vented from the tubular members.

The first and second tubular members 2910 and 2926, and the tubularsleeve 2918 may be positioned within another structure such as, forexample, a wellbore, and radially expanded and plastically deformed, forexample, by displacing and/or rotating an expansion device throughand/or within the interiors of the first and second tubular members.

During the radial expansion and plastic deformation of the first andsecond tubular members 2910 and 2926, the tubular sleeve 2918 is alsoradially expanded and plastically deformed. In an exemplary embodiment,as a result, the tubular sleeve 2918 may be maintained incircumferential tension and the end portions 2916 and 2924, of the firstand second tubular members 2910 and 2926, respectively, may bemaintained in circumferential compression.

In an exemplary embodiment, before, during, and after the radialexpansion and plastic deformation of the first and second tubularmembers 2910 and 2926, and the tubular sleeve 2918, the sealing element2930 seals the interface between the first and second tubular members.In an exemplary embodiment, during and after the radial expansion andplastic deformation of the first and second tubular members 2910 and2926, and the tubular sleeve 2918, a metal to metal seal is formedbetween at least one of: the first and second tubular members 2910 and2926, the first tubular member and the tubular sleeve 2918, and/or thesecond tubular member and the tubular sleeve. In an exemplaryembodiment, the metal to metal seal is both fluid tight and gas tight.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 2910 and 2926, the tubular sleeve 2918, and thesealing element 2930 have one or more of the material properties of oneor more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202and/or 204.

Referring to FIG. 30 a, in an exemplary embodiment, a first tubularmember 3010 includes internally threaded connections 3012 a and 3012 b,spaced apart by a cylindrical internal surface 3014, at an end portion3016. Externally threaded connections 3018 a and 3018 b, spaced apart bya cylindrical external surface 3020, of an end portion 3022 of a secondtubular member 3024 are threadably coupled to the internally threadedconnections, 3012 a and 3012 b, respectively, of the end portion 3016 ofthe first tubular member 3010. A sealing element 3026 is received withinan annulus defined between the internal cylindrical surface 3014 of thefirst tubular member 3010 and the external cylindrical surface 3020 ofthe second tubular member 3024.

The internally threaded connections, 3012 a and 3012 b, of the endportion 3016 of the first tubular member 3010 are box connections, andthe externally threaded connections, 3018 a and 3018 b, of the endportion 3022 of the second tubular member 3024 are pin connections. Inan exemplary embodiment, the sealing element 3026 is an elastomericand/or metallic sealing element.

The first and second tubular members 3010 and 3024 may be positionedwithin another structure such as, for example, a wellbore, and radiallyexpanded and plastically deformed, for example, by displacing and/orrotating an expansion device through and/or within the interiors of thefirst and second tubular members.

In an exemplary embodiment, before, during, and after the radialexpansion and plastic deformation of the first and second tubularmembers 3010 and 3024, the sealing element 3026 seals the interfacebetween the first and second tubular members. In an exemplaryembodiment, before, during and/or after the radial expansion and plasticdeformation of the first and second tubular members 3010 and 3024, ametal to metal seal is formed between at least one of: the first andsecond tubular members 3010 and 3024, the first tubular member and thesealing element 3026, and/or the second tubular member and the sealingelement. In an exemplary embodiment, the metal to metal seal is bothfluid tight and gas tight.

In an alternative embodiment, the sealing element 3026 is omitted, andduring and/or after the radial expansion and plastic deformation of thefirst and second tubular members 3010 and 3024, a metal to metal seal isformed between the first and second tubular members.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 3010 and 3024, the sealing element 3026 have oneor more of the material properties of one or more of the tubular members12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 30 b, in an exemplary embodiment, a first tubularmember 3030 includes internally threaded connections 3032 a and 3032 b,spaced apart by an undulating approximately cylindrical internal surface3034, at an end portion 3036. Externally threaded connections 3038 a and3038 b, spaced apart by a cylindrical external surface 3040, of an endportion 3042 of a second tubular member 3044 are threadably coupled tothe internally threaded connections, 3032 a and 3032 b, respectively, ofthe end portion 3036 of the first tubular member 3030. A sealing element3046 is received within an annulus defined between the undulatingapproximately cylindrical internal surface 3034 of the first tubularmember 3030 and the external cylindrical surface 3040 of the secondtubular member 3044.

The internally threaded connections, 3032 a and 3032 b, of the endportion 3036 of the first tubular member 3030 are box connections, andthe externally threaded connections, 3038 a and 3038 b, of the endportion 3042 of the second tubular member 3044 are pin connections. Inan exemplary embodiment, the sealing element 3046 is an elastomericand/or metallic sealing element.

The first and second tubular members 3030 and 3044 may be positionedwithin another structure such as, for example, a wellbore, and radiallyexpanded and plastically deformed, for example, by displacing and/orrotating an expansion device through and/or within the interiors of thefirst and second tubular members.

In an exemplary embodiment, before, during, and after the radialexpansion and plastic deformation of the first and second tubularmembers 3030 and 3044, the sealing element 3046 seals the interfacebetween the first and second tubular members. In an exemplaryembodiment, before, during and/or after the radial expansion and plasticdeformation of the first and second tubular members 3030 and 3044, ametal to metal seal is formed between at least one of: the first andsecond tubular members 3030 and 3044, the first tubular member and thesealing element 3046, and/or the second tubular member and the sealingelement. In an exemplary embodiment, the metal to metal seal is bothfluid tight and gas tight.

In an alternative embodiment, the sealing element 3046 is omitted, andduring and/or after the radial expansion and plastic deformation of thefirst and second tubular members 3030 and 3044, a metal to metal seal isformed between the first and second tubular members.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 3030 and 3044, the sealing element 3046 have oneor more of the material properties of one or more of the tubular members12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 30 c, in an exemplary embodiment, a first tubularmember 3050 includes internally threaded connections 3052 a and 3052 b,spaced apart by a cylindrical internal surface 3054 including one ormore square grooves 3056, at an end portion 3058. Externally threadedconnections 3060 a and 3060 b, spaced apart by a cylindrical externalsurface 3062 including one or more square grooves 3064, of an endportion 3066 of a second tubular member 3068 are threadably coupled tothe internally threaded connections, 3052 a and 3052 b, respectively, ofthe end portion 3058 of the first tubular member 3050. A sealing element3070 is received within an annulus defined between the cylindricalinternal surface 3054 of the first tubular member 3050 and the externalcylindrical surface 3062 of the second tubular member 3068.

The internally threaded connections, 3052 a and 3052 b, of the endportion 3058 of the first tubular member 3050 are box connections, andthe externally threaded connections, 3060 a and 3060 b, of the endportion 3066 of the second tubular member 3068 are pin connections. Inan exemplary embodiment, the sealing element 3070 is an elastomericand/or metallic sealing element.

The first and second tubular members 3050 and 3068 may be positionedwithin another structure such as, for example, a wellbore, and radiallyexpanded and plastically deformed, for example, by displacing and/orrotating an expansion device through and/or within the interiors of thefirst and second tubular members.

In an exemplary embodiment, before, during, and after the radialexpansion and plastic deformation of the first and second tubularmembers 3050 and 3068, the sealing element 3070 seals the interfacebetween the first and second tubular members. In an exemplaryembodiment, before, during and/or after the radial expansion and plasticdeformation of the first and second tubular members, 3050 and 3068, ametal to metal seal is formed between at least one of: the first andsecond tubular members, the first tubular member and the sealing element3070, and/or the second tubular member and the sealing element. In anexemplary embodiment, the metal to metal seal is both fluid tight andgas tight.

In an alternative embodiment, the sealing element 3070 is omitted, andduring and/or after the radial expansion and plastic deformation of thefirst and second tubular members 950 and 968, a metal to metal seal isformed between the first and second tubular members.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 3050 and 3068, the sealing element 3070 have oneor more of the material properties of one or more of the tubular members12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 31, in an exemplary embodiment, a first tubular member3110 includes internally threaded connections, 3112 a and 3112 b, spacedapart by a non-threaded internal surface 3114, at an end portion 3116.Externally threaded connections, 3118 a and 3118 b, spaced apart by anon-threaded external surface 3120, of an end portion 3122 of a secondtubular member 3124 are threadably coupled to the internally threadedconnections, 3112 a and 3112 b, respectively, of the end portion 3122 ofthe first tubular member 3124.

First, second, and/or third tubular sleeves, 3126, 3128, and 3130, arecoupled the external surface of the first tubular member 3110 inopposing relation to the threaded connection formed by the internal andexternal threads, 3112 a and 3118 a, the interface between thenon-threaded surfaces, 3114 and 3120, and the threaded connection formedby the internal and external threads, 3112 b and 3118 b, respectively.

The internally threaded connections, 3112 a and 3112 b, of the endportion 3116 of the first tubular member 3110 are box connections, andthe externally threaded connections, 3118 a and 3118 b, of the endportion 3122 of the second tubular member 3124 are pin connections.

The first and second tubular members 3110 and 3124, and the tubularsleeves 3126, 3128, and/or 3130, may then be positioned within anotherstructure 3132 such as, for example, a wellbore, and radially expandedand plastically deformed, for example, by displacing and/or rotating anexpansion device 3134 through and/or within the interiors of the firstand second tubular members.

During the radial expansion and plastic deformation of the first andsecond tubular members 3110 and 3124, the tubular sleeves 3126, 3128and/or 3130 are also radially expanded and plastically deformed. In anexemplary embodiment, as a result, the tubular sleeves 3126, 3128,and/or 3130 are maintained in circumferential tension and the endportions 3116 and 3122, of the first and second tubular members 3110 and3124, may be maintained in circumferential compression.

The sleeves 3126, 3128, and/or 3130 may, for example, be secured to thefirst tubular member 3110 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 3110 and 3124, and the sleeves, 3126, 3128, and3130, have one or more of the material properties of one or more of thetubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 32 a, in an exemplary embodiment, a first tubularmember 3210 includes an internally threaded connection 3212 at an endportion 3214. An externally threaded connection 3216 of an end portion3218 of a second tubular member 3220 are threadably coupled to theinternally threaded connection 3212 of the end portion 3214 of the firsttubular member 3210.

The internally threaded connection 3212 of the end portion 3214 of thefirst tubular member 3210 is a box connection, and the externallythreaded connection 3216 of the end portion 3218 of the second tubularmember 3220 is a pin connection.

A tubular sleeve 3222 including internal flanges 3224 and 3226 ispositioned proximate and surrounding the end portion 3214 of the firsttubular member 3210. As illustrated in FIG. 32 b, the tubular sleeve3222 is then forced into engagement with the external surface of the endportion 3214 of the first tubular member 3210 in a conventional manner.As a result, the end portions, 3214 and 3218, of the first and secondtubular members, 3210 and 3220, are upset in an undulating fashion.

The first and second tubular members 3210 and 3220, and the tubularsleeve 3222, may then be positioned within another structure such as,for example, a wellbore, and radially expanded and plastically deformed,for example, by displacing and/or rotating an expansion device throughand/or within the interiors of the first and second tubular members.

During the radial expansion and plastic deformation of the first andsecond tubular members 3210 and 3220, the tubular sleeve 3222 is alsoradially expanded and plastically deformed. In an exemplary embodiment,as a result, the tubular sleeve 3222 is maintained in circumferentialtension and the end portions 3214 and 3218, of the first and secondtubular members 3210 and 3220, may be maintained in circumferentialcompression.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 3210 and 3220, and the sleeve 3222 have one ormore of the material properties of one or more of the tubular members12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 33, in an exemplary embodiment, a first tubular member3310 includes an internally threaded connection 3312 and an annularprojection 3314 at an end portion 3316.

A first end of a tubular sleeve 3318 that includes an internal flange3320 having a tapered portion 3322 and an annular recess 3324 forreceiving the annular projection 3314 of the first tubular member 3310,and a second end that includes a tapered portion 3326, is then mountedupon and receives the end portion 3316 of the first tubular member 3310.

In an exemplary embodiment, the end portion 3316 of the first tubularmember 3310 abuts one side of the internal flange 3320 of the tubularsleeve 3318 and the annular projection 3314 of the end portion of thefirst tubular member mates with and is received within the annularrecess 3324 of the internal flange of the tubular sleeve, and theinternal diameter of the internal flange 3320 of the tubular sleeve 3318is substantially equal to or greater than the maximum internal diameterof the internally threaded connection 3312 of the end portion 3316 ofthe first tubular member 3310. An externally threaded connection 3326 ofan end portion 3328 of a second tubular member 3330 having an annularrecess 3332 is then positioned within the tubular sleeve 3318 andthreadably coupled to the internally threaded connection 3312 of the endportion 3316 of the first tubular member 3310. In an exemplaryembodiment, the internal flange 3332 of the tubular sleeve 3318 mateswith and is received within the annular recess 3332 of the end portion3328 of the second tubular member 3330. Thus, the tubular sleeve 3318 iscoupled to and surrounds the external surfaces of the first and secondtubular members, 3310 and 3328.

The internally threaded connection 3312 of the end portion 3316 of thefirst tubular member 3310 is a box connection, and the externallythreaded connection 3326 of the end portion 3328 of the second tubularmember 3330 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 3318 is at least approximately0.020″ greater than the outside diameters of the first and secondtubular members, 3310 and 3330. In this manner, during the threadedcoupling of the first and second tubular members, 3310 and 3330, fluidicmaterials within the first and second tubular members may be vented fromthe tubular members.

As illustrated in FIG. 33, the first and second tubular members, 3310and 3330, and the tubular sleeve 3318 may be positioned within anotherstructure 3334 such as, for example, a cased or uncased wellbore, andradially expanded and plastically deformed, for example, by displacingand/or rotating a conventional expansion device 3336 within and/orthrough the interiors of the first and second tubular members. Thetapered portions, 3322 and 3326, of the tubular sleeve 3318 facilitatethe insertion and movement of the first and second tubular memberswithin and through the structure 3334, and the movement of the expansiondevice 3336 through the interiors of the first and second tubularmembers, 3310 and 3330, may, for example, be from top to bottom or frombottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members, 3310 and 3330, the tubular sleeve 3318 is alsoradially expanded and plastically deformed. As a result, the tubularsleeve 3318 may be maintained in circumferential tension and the endportions, 3316 and 3328, of the first and second tubular members, 3310and 3330, may be maintained in circumferential compression.

Sleeve 3316 increases the axial compression loading of the connectionbetween tubular members 3310 and 3330 before and after expansion by theexpansion device 3336. Sleeve 3316 may be secured to tubular members3310 and 3330, for example, by a heat shrink fit.

In several alternative embodiments, the first and second tubularmembers, 3310 and 3330, are radially expanded and plastically deformedusing other conventional methods for radially expanding and plasticallydeforming tubular members such as, for example, internal pressurization,hydroforming, and/or roller expansion devices and/or any one orcombination of the conventional commercially available expansionproducts and services available from Baker Hughes, WeatherfordInternational, and/or Enventure Global Technology L.L.C.

The use of the tubular sleeve 3318 during (a) the coupling of the firsttubular member 3310 to the second tubular member 3330, (b) the placementof the first and second tubular members in the structure 3334, and (c)the radial expansion and plastic deformation of the first and secondtubular members provides a number of significant benefits. For example,the tubular sleeve 3318 protects the exterior surfaces of the endportions, 3316 and 3328, of the first and second tubular members, 3310and 3330, during handling and insertion of the tubular members withinthe structure 3334. In this manner, damage to the exterior surfaces ofthe end portions, 3316 and 3328, of the first and second tubularmembers, 3310 and 3330, is avoided that could otherwise result in stressconcentrations that could cause a catastrophic failure during subsequentradial expansion operations. Furthermore, the tubular sleeve 3318provides an alignment guide that facilitates the insertion and threadedcoupling of the second tubular member 3330 to the first tubular member3310. In this manner, misalignment that could result in damage to thethreaded connections, 3312 and 3326, of the first and second tubularmembers, 3310 and 3330, may be avoided. In addition, during the relativerotation of the second tubular member with respect to the first tubularmember, required during the threaded coupling of the first and secondtubular members, the tubular sleeve 3318 provides an indication of towhat degree the first and second tubular members are threadably coupled.For example, if the tubular sleeve 3318 can be easily rotated, thatwould indicate that the first and second tubular members, 3310 and 3330,are not fully threadably coupled and in intimate contact with theinternal flange 3320 of the tubular sleeve. Furthermore, the tubularsleeve 3318 may prevent crack propagation during the radial expansionand plastic deformation of the first and second tubular members, 3310and 3330. In this manner, failure modes such as, for example,longitudinal cracks in the end portions, 3316 and 3328, of the first andsecond tubular members may be limited in severity or eliminated alltogether. In addition, after completing the radial expansion and plasticdeformation of the first and second tubular members, 3310 and 3330, thetubular sleeve 3318 may provide a fluid tight metal-to-metal sealbetween interior surface of the tubular sleeve 3318 and the exteriorsurfaces of the end portions, 3316 and 3328, of the first and secondtubular members. In this manner, fluidic materials are prevented frompassing through the threaded connections, 3312 and 3326, of the firstand second tubular members, 3310 and 3330, into the annulus between thefirst and second tubular members and the structure 3334. Furthermore,because, following the radial expansion and plastic deformation of thefirst and second tubular members, 3310 and 3330, the tubular sleeve 3318may be maintained in circumferential tension and the end portions, 3316and 3328, of the first and second tubular members, 3310 and 3330, may bemaintained in circumferential compression, axial loads and/or torqueloads may be transmitted through the tubular sleeve.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 3310 and 3330, and the sleeve 3318 have one ormore of the material properties of one or more of the tubular members12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIGS. 34 a, 34 b, and 34 c, in an exemplary embodiment, afirst tubular member 3410 includes an internally threaded connection1312 and one or more external grooves 3414 at an end portion 3416.

A first end of a tubular sleeve 3418 that includes an internal flange3420 and a tapered portion 3422, a second end that includes a taperedportion 3424, and an intermediate portion that includes one or morelongitudinally aligned openings 3426, is then mounted upon and receivesthe end portion 3416 of the first tubular member 3410.

In an exemplary embodiment, the end portion 3416 of the first tubularmember 3410 abuts one side of the internal flange 3420 of the tubularsleeve 3418, and the internal diameter of the internal flange 3420 ofthe tubular sleeve 3416 is substantially equal to or greater than themaximum internal diameter of the internally threaded connection 3412 ofthe end portion 3416 of the first tubular member 3410. An externallythreaded connection 3428 of an end portion 3430 of a second tubularmember 3432 that includes one or more internal grooves 3434 is thenpositioned within the tubular sleeve 3418 and threadably coupled to theinternally threaded connection 3412 of the end portion 3416 of the firsttubular member 3410. In an exemplary embodiment, the internal flange3420 of the tubular sleeve 3418 mates with and is received within anannular recess 3436 defined in the end portion 3430 of the secondtubular member 3432. Thus, the tubular sleeve 3418 is coupled to andsurrounds the external surfaces of the first and second tubular members,3410 and 3432.

The first and second tubular members, 3410 and 3432, and the tubularsleeve 3418 may be positioned within another structure such as, forexample, a cased or uncased wellbore, and radially expanded andplastically deformed, for example, by displacing and/or rotating aconventional expansion device within and/or through the interiors of thefirst and second tubular members. The tapered portions, 3422 and 3424,of the tubular sleeve 3418 facilitate the insertion and movement of thefirst and second tubular members within and through the structure, andthe movement of the expansion device through the interiors of the firstand second tubular members, 3410 and 3432, may be from top to bottom orfrom bottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members, 3410 and 3432, the tubular sleeve 3418 is alsoradially expanded and plastically deformed. As a result, the tubularsleeve 3418 may be maintained in circumferential tension and the endportions, 3416 and 3430, of the first and second tubular members, 3410and 3432, may be maintained in circumferential compression.

Sleeve 3416 increases the axial compression loading of the connectionbetween tubular members 3410 and 3432 before and after expansion by theexpansion device. The sleeve 3418 may be secured to tubular members 3410and 3432, for example, by a heat shrink fit.

During the radial expansion and plastic deformation of the first andsecond tubular members, 3410 and 3432, the grooves 3414 and/or 3434and/or the openings 3426 provide stress concentrations that in turnapply added stress forces to the mating threads of the threadedconnections, 3412 and 3428. As a result, during and after the radialexpansion and plastic deformation of the first and second tubularmembers, 3410 and 3432, the mating threads of the threaded connections,3412 and 3428, are maintained in metal to metal contact therebyproviding a fluid and gas tight connection. In an exemplary embodiment,the orientations of the grooves 3414 and/or 3434 and the openings 3426are orthogonal to one another. In an exemplary embodiment, the grooves3414 and/or 3434 are helical grooves.

In several alternative embodiments, the first and second tubularmembers, 3410 and 3432, are radially expanded and plastically deformedusing other conventional methods for radially expanding and plasticallydeforming tubular members such as, for example, internal pressurization,hydroforming, and/or roller expansion devices and/or any one orcombination of the conventional commercially available expansionproducts and services available from Baker Hughes, WeatherfordInternational, and/or Enventure Global Technology L.L.C.

The use of the tubular sleeve 3418 during (a) the coupling of the firsttubular member 3410 to the second tubular member 3432, (b) the placementof the first and second tubular members in the structure, and (c) theradial expansion and plastic deformation of the first and second tubularmembers provides a number of significant benefits. For example, thetubular sleeve 3418 protects the exterior surfaces of the end portions,3416 and 3430, of the first and second tubular members, 3410 and 3432,during handling and insertion of the tubular members within thestructure. In this manner, damage to the exterior surfaces of the endportions, 3416 and 3430, of the first and second tubular members, 3410and 3432, is avoided that could otherwise result in stressconcentrations that could cause a catastrophic failure during subsequentradial expansion operations. Furthermore, the tubular sleeve 3418provides an alignment guide that facilitates the insertion and threadedcoupling of the second tubular member 3432 to the first tubular member3410. In this manner, misalignment that could result in damage to thethreaded connections, 3412 and 3428, of the first and second tubularmembers, 3410 and 3432, may be avoided. In addition, during the relativerotation of the second tubular member with respect to the first tubularmember, required during the threaded coupling of the first and secondtubular members, the tubular sleeve 3416 provides an indication of towhat degree the first and second tubular members are threadably coupled.For example, if the tubular sleeve 3418 can be easily rotated, thatwould indicate that the first and second tubular members, 3410 and 3432,are not fully threadably coupled and in intimate contact with theinternal flange 3420 of the tubular sleeve. Furthermore, the tubularsleeve 3418 may prevent crack propagation during the radial expansionand plastic deformation of the first and second tubular members, 3410and 3432. In this manner, failure modes such as, for example,longitudinal cracks in the end portions, 3416 and 3430, of the first andsecond tubular members may be limited in severity or eliminated alltogether. In addition, after completing the radial expansion and plasticdeformation of the first and second tubular members, 3410 and 3432, thetubular sleeve 3418 may provide a fluid and gas tight metal-to-metalseal between interior surface of the tubular sleeve 3418 and theexterior surfaces of the end portions, 3416 and 3430, of the first andsecond tubular members. In this manner, fluidic materials are preventedfrom passing through the threaded connections, 3412 and 3430, of thefirst and second tubular members, 3410 and 3432, into the annulusbetween the first and second tubular members and the structure.Furthermore, because, following the radial expansion and plasticdeformation of the first and second tubular members, 3410 and 3432, thetubular sleeve 3418 may be maintained in circumferential tension and theend portions, 3416 and 3430, of the first and second tubular members,3410 and 3432, may be maintained in circumferential compression, axialloads and/or torque loads may be transmitted through the tubular sleeve.

In several exemplary embodiments, the first and second tubular membersdescribed above with reference to FIGS. 1 to 34 c are radially expandedand plastically deformed using the expansion device in a conventionalmanner and/or using one or more of the methods and apparatus disclosedin one or more of the following: (1) U.S. Pat. No. 6,497,289, which wasfiled as U.S. patent application Ser. No. 09/454,139, attorney docketno. 25791.03.02, filed on Dec. 3, 1999, which claims priority fromprovisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S.patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02,filed on Feb. 23, 2000, which claims priority from provisionalapplication 60/121,702, filed on Feb. 25, 1999, (3) U.S. patentapplication Ser. No. 09/502,350, attorney docket no. 25791.8.02, filedon Feb. 10, 2000, which claims priority from provisional application60/119,611, filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, whichwas filed as U.S. patent application Ser. No. 09/440,338, attorneydocket number 25791.9.02, filed on Nov. 15, 1999, which claims priorityfrom provisional application 60/108,558, filed on Nov. 16, 1998, (5)U.S. patent application Ser. No. 10/169,434, attorney docket no.25791.10.04, filed on Jul. 1, 2002, which claims priority fromprovisional application 60/183,546, filed on Feb. 18, 2000, (6) U.S.Pat. No. 6,640,903 which was filed as U.S. patent application Ser. No.09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claims priority from provisional application 60/124,042, filed onMar. 11, 1999, (7) U.S. Pat. No. 6,568,471, which was filed as patentapplication Ser. No. 09/512,895, attorney docket no. 25791.12.02, filedon Feb. 24, 2000, which claims priority from provisional application60/121,841, filed on Feb. 26, 1999, (8) U.S. Pat. No. 6,575,240, whichwas filed as patent application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claims priority fromprovisional application 60/121,907, filed on Feb. 26, 1999, (9) U.S.Pat. No. 6,557,640, which was filed as patent application Ser. No.09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, whichclaims priority from provisional application 60/137,998, filed on Jun.7, 1999, (10) U.S. patent application Ser. No. 09/981,916, attorneydocket no. 25791.18, filed on Oct. 18, 2001 as a continuation-in-partapplication of U.S. Pat. No. 6,328,113, which was filed as U.S. patentapplication Ser. No. 09/440,338, attorney docket number 25791.9.02,filed on Nov. 15, 1999, which claims priority from provisionalapplication 60/108,558, filed on Nov. 16, 1998, (11) U.S. Pat. No.6,604,763, which was filed as application Ser. No. 09/559,122, attorneydocket no. 25791.23.02, filed on Apr. 26, 2000, which claims priorityfrom provisional application 60/131,106, filed on Apr. 26, 1999, (12)U.S. patent application Ser. No. 10/030,593, attorney docket no.25791.25.08, filed on Jan. 8, 2002, which claims priority fromprovisional application 60/146,203, filed on Jul. 29, 1999, (13) U.S.provisional patent application Ser. No. 60/143,039, attorney docket no.25791.26, filed on Jul. 9, 1999, (14) U.S. patent application Ser. No.10/111,982, attorney docket no. 25791.27.08, filed on Apr. 30, 2002,which claims priority from provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999, (15)U.S. provisional patent application Ser. No. 60/154,047, attorney docketno. 25791.29, filed on Sep. 16, 1999, (16) U.S. provisional patentapplication Ser. No. 60/438,828, attorney docket no. 25791.31, filed onJan. 9, 2003, (17) U.S. Pat. No. 6,564,875, which was filed asapplication Ser. No. 09/679,907, attorney docket no. 25791.34.02, onOct. 5, 2000, which claims priority from provisional patent applicationSer. No. 60/159,082, attorney docket no. 25791.34, filed on Oct. 12,1999, (18) U.S. patent application Ser. No. 10/089,419, filed on Mar.27, 2002, attorney docket no. 25791.36.03, which claims priority fromprovisional patent application Ser. No. 60/159,039, attorney docket no.25791.36, filed on Oct. 12, 1999, (19) U.S. patent application Ser. No.09/679,906, filed on Oct. 5, 2000, attorney docket no. 25791.37.02,which claims priority from provisional patent application Ser. No.60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999, (20)U.S. patent application Ser. No. 10/303,992, filed on Nov. 22, 2002,attorney docket no. 25791.38.07, which claims priority from provisionalpatent application Ser. No. 60/212,359, attorney docket no. 25791.38,filed on Jun. 19, 2000, (21) U.S. provisional patent application Ser.No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999,(22) U.S. provisional patent application Ser. No. 60/455,051, attorneydocket no. 25791.40, filed on Mar. 14, 2003, (23) PCT applicationUS02/2477, filed on Jun. 26, 2002, attorney docket no. 25791.44.02,which claims priority from U.S. provisional patent application Ser. No.60/303,711, attorney docket no. 25791.44, filed on Jul. 6, 2001, (24)U.S. patent application Ser. No. 10/311,412, filed on Dec. 12, 2002,attorney docket no. 25791.45.07, which claims priority from provisionalpatent application Ser. No. 60/221,443, attorney docket no. 25791.45,filed on Jul. 28, 2000, (25) U.S. patent application Ser. No. 10/, filedon Dec. 18, 2002, attorney docket no. 25791.46.07, which claims priorityfrom provisional patent application Ser. No. 60/221,645, attorney docketno. 25791.46, filed on Jul. 28, 2000, (26) U.S. patent application Ser.No. 10/322,947, filed on 1/22/03, attorney docket no. 25791.47.03, whichclaims priority from provisional patent application Ser. No. 60/233,638,attorney docket no. 25791.47, filed on Sep. 18, 2000, (27) U.S. patentapplication Ser. No. 10/406,648, filed on Mar. 31, 2003, attorney docketno. 25791.48.06, which claims priority from provisional patentapplication Ser. No. 60/237,334, attorney docket no. 25791.48, filed onOct. 2, 2000, (28) PCT application US02/04353, filed on Feb. 14, 2002,attorney docket no. 25791.50.02, which claims priority from U.S.provisional patent application Ser. No. 60/270,007, attorney docket no.25791.50, filed on Feb. 20, 2001, (29) U.S. patent application Ser. No.10/465,835, filed on Jun. 13, 2003, attorney docket no. 25791.51.06,which claims priority from provisional patent application Ser. No.60/262,434, attorney docket no. 25791.51, filed on Jan. 17, 2001, (30)U.S. patent application Ser. No. 10/465,831, filed on Jun. 13, 2003,attorney docket no. 25791.52.06, which claims priority from U.S.provisional patent application Ser. No. 60/259,486, attorney docket no.25791.52, filed on Jan. 3, 2001, (31) U.S. provisional patentapplication Ser. No. 60/452,303, filed on Mar. 5, 2003, attorney docketno. 25791.53, (32) U.S. Pat. No. 6,470,966, which was filed as patentapplication Ser. No. 09/850,093, filed on May 7, 2001, attorney docketno. 25791.55, as a divisional application of U.S. Pat. No. 6,497,289,which was filed as U.S. patent application Ser. No. 09/454,139, attorneydocket no. 25791.03.02, filed on Dec. 3, 1999, which claims priorityfrom provisional application 60/111,293, filed on Dec. 7, 1998, (33)U.S. Pat. No. 6,561,227, which was filed as patent application Ser. No.09/852,026, filed on May 9, 2001, attorney docket no. 25791.56, as adivisional application of U.S. Pat. No. 6,497,289, which was filed asU.S. patent application Ser. No. 09/454,139, attorney docket no.25791.03.02, filed on Dec. 3, 1999, which claims priority fromprovisional application 60/111,293, filed on Dec. 7, 1998, (34) U.S.patent application Ser. No. 09/852,027, filed on May 9, 2001, attorneydocket no. 25791.57, as a divisional application of U.S. Pat. No.6,497,289, which was filed as U.S. patent application Ser. No.09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,which claims priority from provisional application 60/111,293, filed onDec. 7, 1998, (35) PCT Application US02/25608, attorney docket no.25791.58.02, filed on Aug. 13, 2002, which claims priority fromprovisional application 60/318,021, filed on Sep. 7, 2001, attorneydocket no. 25791.58, (36) PCT Application US02/24399, attorney docketno. 25791.59.02, filed on Aug. 1, 2002, which claims priority from U.S.provisional patent application Ser. No. 60/313,453, attorney docket no.25791.59, filed on Aug. 20, 2001, (37) PCT Application US02/29856,attorney docket no. 25791.60.02, filed on Sep. 19, 2002, which claimspriority from U.S. provisional patent application Ser. No. 60/326,886,attorney docket no. 25791.60, filed on Oct. 3, 2001, (38) PCTApplication US02/20256, attorney docket no. 25791.61.02, filed on Jun.26, 2002, which claims priority from U.S. provisional patent applicationSer. No. 60/303,740, attorney docket no. 25791.61, filed on Jul. 6,2001, (39) U.S. patent application Ser. No. 09/962,469, filed on Sep.25, 2001, attorney docket no. 25791.62, which is a divisional of U.S.patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02,filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903 which issued Nov.4, 2003), which claims priority from provisional application 60/124,042,filed on Mar. 11, 1999, (40) U.S. patent application Ser. No.09/962,470, filed on Sep. 25, 2001, attorney docket no. 25791.63, whichis a divisional of U.S. patent application Ser. No. 09/523,468, attorneydocket no. 25791.11.02, filed on Mar. 10, 2000, (now U.S. Pat. No.6,640,903 which issued Nov. 4, 2003), which claims priority fromprovisional application 60/124,042, filed on Mar. 11, 1999, (41) U.S.patent application Ser. No. 09/962,471, filed on Sep. 25, 2001, attorneydocket no. 25791.64, which is a divisional of U.S. patent applicationSer. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10,2000, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003), whichclaims priority from provisional application 60/124,042, filed on Mar.11, 1999, (42) U.S. patent application Ser. No. 09/962,467, filed onSep. 25, 2001, attorney docket no. 25791.65, which is a divisional ofU.S. patent application Ser. No. 09/523,468, attorney docket no.25791.11.02, filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903 whichissued Nov. 4, 2003), which claims priority from provisional application60/124,042, filed on Mar. 11, 1999, (43) U.S. patent application Ser.No. 09/962,468, filed on Sep. 25, 2001, attorney docket no. 25791.66,which is a divisional of U.S. patent application Ser. No. 09/523,468,attorney docket no. 25791.11.02, filed on Mar. 10, 2000, (now U.S. Pat.No. 6,640,903 which issued Nov. 4, 2003), which claims priority fromprovisional application 60/124,042, filed on Mar. 11, 1999, (44) PCTapplication US 02/25727, filed on Aug. 14, 2002, attorney docket no.25791.67.03, which claims priority from U.S. provisional patentapplication Ser. No. 60/317,985, attorney docket no. 25791.67, filed onSep. 6, 2001, and U.S. provisional patent application Ser. No.60/318,386, attorney docket no. 25791.67.02, filed on Sep. 10, 2001,(45) PCT application US 02/39425, filed on Dec. 10, 2002, attorneydocket no. 25791.68.02, which claims priority from U.S. provisionalpatent application Ser. No. 60/343,674, attorney docket no. 25791.68,filed on Dec. 27, 2001, (46) U.S. utility patent application Ser. No.09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001, (nowU.S. Pat. No. 6,634,431 which issued Oct. 21, 2003), which is acontinuation-in-part application of U.S. Pat. No. 6,328,113, which wasfiled as U.S. patent application Ser. No. 09/440,338, attorney docketnumber 25791.9.02, filed on Nov. 15, 1999, which claims priority fromprovisional application 60/108,558, filed on Nov. 16, 1998, (47) U.S.utility patent application Ser. No. 10/516,467, attorney docket no.25791.70, filed on Dec. 10, 2001, which is a continuation application ofU.S. utility patent application Ser. No. 09/969,922, attorney docket no.25791.69, filed on Oct. 3, 2001, (now U.S. Pat. No. 6,634,431 whichissued Oct. 21, 2003), which is a continuation-in-part application ofU.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser.No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15,1999, which claims priority from provisional application 60/108,558,filed on Nov. 16, 1998, (48) PCT application US 03/00609, filed on Jan.9, 2003, attorney docket no. 25791.71.02, which claims priority fromU.S. provisional patent application Ser. No. 60/357,372, attorney docketno. 25791.71, filed on Feb. 15, 2002, (49) U.S. patent application Ser.No. 10/074,703, attorney docket no. 25791.74, filed on Feb. 12, 2002,which is a divisional of U.S. Pat. No. 6,568,471, which was filed aspatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claims priority from provisionalapplication 60/121,841, filed on Feb. 26, 1999, (50) U.S. patentapplication Ser. No. 10/074,244, attorney docket no. 25791.75, filed onFeb. 12, 2002, which is a divisional of U.S. Pat. No. 6,568,471, whichwas filed as patent application Ser. No. 09/512,895, attorney docket no.25791.12.02, filed on Feb. 24, 2000, which claims priority fromprovisional application 60/121,841, filed on Feb. 26, 1999, (51) U.S.patent application Ser. No. 10/076,660, attorney docket no. 25791.76,filed on Feb. 15, 2002, which is a divisional of U.S. Pat. No.6,568,471, which was filed as patent application Ser. No. 09/512,895,attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimspriority from provisional application 60/121,841, filed on Feb. 26,1999, (52) U.S. patent application Ser. No. 10/076,661, attorney docketno. 25791.77, filed on Feb. 15, 2002, which is a divisional of U.S. Pat.No. 6,568,471, which was filed as patent application Ser. No.09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000,which claims priority from provisional application 60/121,841, filed onFeb. 26, 1999, (53) U.S. patent application Ser. No. 10/076,659,attorney docket no. 25791.78, filed on Feb. 15, 2002, which is adivisional of U.S. Pat. No. 6,568,471, which was filed as patentapplication Ser. No. 09/512,895, attorney docket no. 25791.12.02, filedon Feb. 24, 2000, which claims priority from provisional application60/121,841, filed on Feb. 26, 1999, (54) U.S. patent application Ser.No. 10/078,928, attorney docket no. 25791.79, filed on Feb. 20, 2002,which is a divisional of U.S. Pat. No. 6,568,471, which was filed aspatent application Ser. No. 09/512,895, attorney docket no. 25791.12.02,filed on Feb. 24, 2000, which claims priority from provisionalapplication 60/121,841, filed on Feb. 26, 1999, (55) U.S. patentapplication Ser. No. 10/078,922, attorney docket no. 25791.80, filed onFeb. 20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, whichwas filed as patent application Ser. No. 09/512,895, attorney docket no.25791.12.02, filed on Feb. 24, 2000, which claims priority fromprovisional application 60/121,841, filed on Feb. 26, 1999, (56) U.S.patent application Ser. No. 10/078,921, attorney docket no. 25791.81,filed on Feb. 20, 2002, which is a divisional of U.S. Pat. No.6,568,471, which was filed as patent application Ser. No. 09/512,895,attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimspriority from provisional application 60/121,841, filed on Feb. 26,1999, (57) U.S. patent application Ser. No. 10/261,928, attorney docketno. 25791.82, filed on Oct. 1, 2002, which is a divisional of U.S. Pat.No. 6,557,640, which was filed as patent application Ser. No.09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,which claims priority from provisional application 60/137,998, filed onJun. 7, 1999, (58) U.S. patent application Ser. No. 10/079,276, attorneydocket no. 25791.83, filed on Feb. 20, 2002, which is a divisional ofU.S. Pat. No. 6,568,471, which was filed as patent application Ser. No.09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000,which claims priority from provisional application 60/121,841, filed onFeb. 26, 1999, (59) U.S. patent application Ser. No. 10/262,009,attorney docket no. 25791.84, filed on Oct. 1, 2002, which is adivisional of U.S. Pat. No. 6,557,640, which was filed as patentapplication Ser. No. 09/588,946, attorney docket no. 25791.17.02, filedon Jun. 7, 2000, which claims priority from provisional application60/137,998, filed on Jun. 7, 1999, (60) U.S. patent application Ser. No.10/092,481, attorney docket no. 25791.85, filed on Mar. 7, 2002, whichis a divisional of U.S. Pat. No. 6,568,471, which was filed as patentapplication Ser. No. 09/512,895, attorney docket no. 25791.12.02, filedon Feb. 24, 2000, which claims priority from provisional application60/121,841, filed on Feb. 26, 1999, (61) U.S. patent application Ser.No. 10/261,926, attorney docket no. 25791.86, filed on Oct. 1, 2002,which is a divisional of U.S. Pat. No. 6,557,640, which was filed aspatent application Ser. No. 09/588,946, attorney docket no. 25791.17.02,filed on Jun. 7, 2000, which claims priority from provisionalapplication 60/137,998, filed on Jun. 7, 1999, (62) PCT application US02/36157, filed on Nov. 12, 2002, attorney docket no. 25791.87.02, whichclaims priority from U.S. provisional patent application Ser. No.60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001, (63)PCT application US 02/36267, filed on Nov. 12, 2002, attorney docket no.25791.88.02, which claims priority from U.S. provisional patentapplication Ser. No. 60/339,013, attorney docket no. 25791.88, filed onNov. 12, 2001, (64) PCT application US 03/11765, filed on Apr. 16, 2003,attorney docket no. 25791.89.02, which claims priority from U.S.provisional patent application Ser. No. 60/383,917, attorney docket no.25791.89, filed on May 29, 2002, (65) PCT application US 03/15020, filedon May 12, 2003, attorney docket no. 25791.90.02, which claims priorityfrom U.S. provisional patent application Ser. No. 60/391,703, attorneydocket no. 25791.90, filed on Jun. 26, 2002, (66) PCT application US02/39418, filed on Dec. 10, 2002, attorney docket no. 25791.92.02, whichclaims priority from U.S. provisional patent application Ser. No.60/346,309, attorney docket no. 25791.92, filed on Jan. 7, 2002, (67)PCT application US 03/06544, filed on Mar. 4, 2003, attorney docket no.25791.93.02, which claims priority from U.S. provisional patentapplication Ser. No. 60/372,048, attorney docket no. 25791.93, filed onApr. 12, 2002, (68) U.S. patent application Ser. No. 10/331,718,attorney docket no. 25791.94, filed on Dec. 30, 2002, which is adivisional U.S. patent application Ser. No. 09/679,906, filed on Oct. 5,2000, attorney docket no. 25791.37.02, which claims priority fromprovisional patent application Ser. No. 60/159,033, attorney docket no.25791.37, filed on Oct. 12, 1999, (69) PCT application US 03/04837,filed on Feb. 29, 2003, attorney docket no. 25791.95.02, which claimspriority from U.S. provisional patent application Ser. No. 60/363,829,attorney docket no. 25791.95, filed on Mar. 13, 2002, (70) U.S. patentapplication Ser. No. 10/261,927, attorney docket no. 25791.97, filed onOct. 1, 2002, which is a divisional of U.S. Pat. No. 6,557,640, whichwas filed as patent application Ser. No. 09/588,946, attorney docket no.25791.17.02, filed on Jun. 7, 2000, which claims priority fromprovisional application 60/137,998, filed on Jun. 7, 1999, (71) U.S.patent application Ser. No. 10/262,008, attorney docket no. 25791.98,filed on Oct. 1, 2002, which is a divisional of U.S. Pat. No. 6,557,640,which was filed as patent application Ser. No. 09/588,946, attorneydocket no. 25791.17.02, filed on Jun. 7, 2000, which claims priorityfrom provisional application 60/137,998, filed on Jun. 7, 1999, (72)U.S. patent application Ser. No. 10/261,925, attorney docket no.25791.99, filed on Oct. 1, 2002, which is a divisional of U.S. Pat. No.6,557,640, which was filed as patent application Ser. No. 09/588,946,attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimspriority from provisional application 60/137,998, filed on Jun. 7, 1999,(73) U.S. patent application Ser. No. 10/199,524, attorney docket no.25791.100, filed on Jul. 19, 2002, which is a continuation of U.S. Pat.No. 6,497,289, which was filed as U.S. patent application Ser. No.09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,which claims priority from provisional application 60/111,293, filed onDec. 7, 1998, (74) PCT application US 03/10144, filed on Mar. 28, 2003,attorney docket no. 25791.101.02, which claims priority from U.S.provisional patent application Ser. No. 60/372,632, attorney docket no.25791.101, filed on Apr. 15, 2002, (75) U.S. provisional patentapplication Ser. No. 60/412,542, attorney docket no. 25791.102, filed onSep. 20, 2002, (76) PCT application US 03/14153, filed on May 6, 2003,attorney docket no. 25791.104.02, which claims priority from U.S.provisional patent application Ser. No. 60/380,147, attorney docket no.25791.104, filed on May 6, 2002, (77) PCT application US 03/19993, filedon Jun. 24, 2003, attorney docket no. 25791.106.02, which claimspriority from U.S. provisional patent application Ser. No. 60/397,284,attorney docket no. 25791.106, filed on Jul. 19, 2002, (78) PCTapplication US 03/13787, filed on May 5, 2003, attorney docket no.25791.107.02, which claims priority from U.S. provisional patentapplication Ser. No. 60/387,486, attorney docket no. 25791.107, filed onJun. 10, 2002, (79) PCT application US 03/18530, filed on Jun. 11, 2003,attorney docket no. 25791.108.02, which claims priority from U.S.provisional patent application Ser. No. 60/387,961, attorney docket no.25791.108, filed on Jun. 12, 2002, (80) PCT application US 03/20694,filed on Jul. 1, 2003, attorney docket no. 25791.110.02, which claimspriority from U.S. provisional patent application Ser. No. 60/398,061,attorney docket no. 25791.110, filed on Jul. 24, 2002, (81) PCTapplication US 03/20870, filed on Jul. 2, 2003, attorney docket no.25791.111.02, which claims priority from U.S. provisional patentapplication Ser. No. 60/399,240, attorney docket no. 25791.111, filed onJul. 29, 2002, (82) U.S. provisional patent application Ser. No.60/412,487, attorney docket no. 25791.112, filed on Sep. 20, 2002, (83)U.S. provisional patent application Ser. No. 60/412,488, attorney docketno. 25791.114, filed on Sep. 20, 2002, (84) U.S. patent application Ser.No. 10/280,356, attorney docket no. 25791.115, filed on Oct. 25, 2002,which is a continuation of U.S. Pat. No. 6,470,966, which was filed aspatent application Ser. No. 09/850,093, filed on May 7, 2001, attorneydocket no. 25791.55, as a divisional application of U.S. Pat. No.6,497,289, which was filed as U.S. patent application Ser. No.09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,which claims priority from provisional application 60/111,293, filed onDec. 7, 1998, (85) U.S. provisional patent application Ser. No.60/412,177, attorney docket no. 25791.117, filed on Sep. 20, 2002, (86)U.S. provisional patent application Ser. No. 60/412,653, attorney docketno. 25791.118, filed on Sep. 20, 2002, (87) U.S. provisional patentapplication Ser. No. 60/405,610, attorney docket no. 25791.119, filed onAug. 23, 2002, (88) U.S. provisional patent application Ser. No.60/405,394, attorney docket no. 25791.120, filed on Aug. 23, 2002, (89)U.S. provisional patent application Ser. No. 60/412,544, attorney docketno. 25791.121, filed on Sep. 20, 2002, (90) PCT application US 03/24779,filed on Aug. 8, 2003, attorney docket no. 25791.125.02, which claimspriority from U.S. provisional patent application Ser. No. 60/407,442,attorney docket no. 25791.125, filed on Aug. 30, 2002, (91) U.S.provisional patent application Ser. No. 60/423,363, attorney docket no.25791.126, filed on Dec. 10, 2002, (92) U.S. provisional patentapplication Ser. No. 60/412,196, attorney docket no. 25791.127, filed onSep. 20, 2002, (93) U.S. provisional patent application Ser. No.60/412,187, attorney docket no. 25791.128, filed on Sep. 20, 2002, (94)U.S. provisional patent application Ser. No. 60/412,371, attorney docketno. 25791.129, filed on Sep. 20, 2002, (95) U.S. patent application Ser.No. 10/382,325, attorney docket no. 25791.145, filed on Mar. 5, 2003,which is a continuation of U.S. Pat. No. 6,557,640, which was filed aspatent application Ser. No. 09/588,946, attorney docket no. 25791.17.02,filed on Jun. 7, 2000, which claims priority from provisionalapplication 60/137,998, filed on Jun. 7, 1999, (96) U.S. patentapplication Ser. No. 10/624,842, attorney docket no. 25791.151, filed onJul. 22, 2003, which is a divisional of U.S. patent application Ser. No.09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000,which claims priority from provisional application 60/119,611, filed onFeb. 11, 1999, (97) U.S. provisional patent application Ser. No.60/431,184, attorney docket no. 25791.157, filed on Dec. 5, 2002, (98)U.S. provisional patent application Ser. No. 60/448,526, attorney docketno. 25791.185, filed on Feb. 18, 2003, (99) U.S. provisional patentapplication Ser. No. 60/461,539, attorney docket no. 25791.186, filed onApr. 9, 2003, (100) U.S. provisional patent application Ser. No.60/462,750, attorney docket no. 25791.193, filed on Apr. 14, 2003, (101)U.S. provisional patent application Ser. No. 60/436,106, attorney docketno. 25791.200, filed on Dec. 23, 2002, (102) U.S. provisional patentapplication Ser. No. 60/442,942, attorney docket no. 25791.213, filed onJan. 27, 2003, (103) U.S. provisional patent application Ser. No.60/442,938, attorney docket no. 25791.225, filed on Jan. 27, 2003, (104)U.S. provisional patent application Ser. No. 60/418,687, attorney docketno. 25791.228, filed on Apr. 18, 2003, (105) U.S. provisional patentapplication Ser. No. 60/454,896, attorney docket no. 25791.236, filed onMar. 14, 2003, (106) U.S. provisional patent application Ser. No.60/450,504, attorney docket no. 25791.238, filed on Feb. 26, 2003, (107)U.S. provisional patent application Ser. No. 60/451,152, attorney docketno. 25791.239, filed on Mar. 9, 2003, (108) U.S. provisional patentapplication Ser. No. 60/455,124, attorney docket no. 25791.241, filed onMar. 17, 2003, (109) U.S. provisional patent application Ser. No.60/453,678, attorney docket no. 25791.253, filed on Mar. 11, 2003, (110)U.S. patent application Ser. No. 10/421,682, attorney docket no.25791.256, filed on Apr. 23, 2003, which is a continuation of U.S.patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02,filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903 which issued Nov.4, 2003), which claims priority from provisional application 60/124,042,filed on Mar. 11, 1999, (111) U.S. provisional patent application Ser.No. 60/457,965, attorney docket no. 25791.260, filed on Mar. 27, 2003,(112) U.S. provisional patent application Ser. No. 60/455,718, attorneydocket no. 25791.262, filed on Mar. 18, 2003, (113) U.S. Pat. No.6,550,821, which was filed as patent application Ser. No. 09/811,734,filed on Mar. 19, 2001, (114) U.S. patent application Ser. No.10/436,467, attorney docket no. 25791.268, filed on May 12, 2003, whichis a continuation of U.S. Pat. No. 6,604,763, which was filed asapplication Ser. No. 09/559,122, attorney docket no. 25791.23.02, filedon Apr. 26, 2000, which claims priority from provisional application60/131,106, filed on Apr. 26, 1999, (115) U.S. provisional patentapplication Ser. No. 60/459,776, attorney docket no. 25791.270, filed onApr. 2, 2003, (116) U.S. provisional patent application Ser. No.60/461,094, attorney docket no. 25791.272, filed on Apr. 8, 2003, (117)U.S. provisional patent application Ser. No. 60/461,038, attorney docketno. 25791.273, filed on Apr. 7, 2003, (118) U.S. provisional patentapplication Ser. No. 60/463,586, attorney docket no. 25791.277, filed onApr. 17, 2003, (119) U.S. provisional patent application Ser. No.60/472,240, attorney docket no. 25791.286, filed on May 20, 2003, (120)U.S. patent application Ser. No. 10/619,285, attorney docket no.25791.292, filed on Jul. 14, 2003, which is a continuation-in-part ofU.S. utility patent application Ser. No. 09/969,922, attorney docket no.25791.69, filed on Oct. 3, 2001, (now U.S. Pat. No. 6,634,431 whichissued Oct. 21, 2003), which is a continuation-in-part application ofU.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser.No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15,1999, which claims priority from provisional application 60/108,558,filed on Nov. 16, 1998, (121) U.S. utility patent application Ser. No.10/418,688, attorney docket no. 25791.257, which was filed on Apr. 18,2003, as a division of U.S. utility patent application Ser. No.09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,(now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003), which claimspriority from provisional application 60/124,042, filed on Mar. 11,1999; (122) PCT patent application serial no. PCT/US2004/06246, attorneydocket no. 25791.238.02, filed on Feb. 26, 2004; (123) PCT patentapplication serial number PCT/US2004/08170, attorney docket number25791.40.02, filed on Mar. 15, 2004; (124) PCT patent application serialnumber PCT/US2004/08171, attorney docket number 25791.236.02, filed onMar. 15, 2004; (125) PCT patent application serial numberPCT/US2004/08073, attorney docket number 25791.262.02, filed on Mar. 18,2004; (126) PCT patent application serial number PCT/US2004/07711,attorney docket number 25791.253.02, filed on Mar. 11, 2004; (127) PCTpatent application serial number PCT/US2004/029025, attorney docketnumber 25791.260.02, filed on Mar. 26, 2004; (128) PCT patentapplication serial number PCT/US2004/010317, attorney docket number25791.270.02, filed on Apr. 2, 2004; (129) PCT patent application serialnumber PCT/US2004/010712, attorney docket number 25791.272.02, filed onApr. 6, 2004; (130) PCT patent application serial numberPCT/US2004/010762, attorney docket number 25791.273.02, filed on Apr. 6,2004; (131) PCT patent application serial number PCT/US2004/011973,attorney docket number 25791.277.02, filed on Apr. 15, 2004; (132) U.S.provisional patent application Ser. No. 60/495,056, attorney docketnumber 25791.301, filed on Aug. 14, 2003; (133) U.S. provisional patentapplication Ser. No. 60/600,679, attorney docket number 25791.194, filedon Aug. 11, 2004; (134) PCT patent application serial numberPCT/US2005/027318, attorney docket number 25791.329.02, filed on Jul.29, 2005; (135) PCT patent application serial number PCT/US2005/028936,attorney docket number 25791.338.02, filed on Aug. 12, 2005; (136) PCTpatent application serial number PCT/US2005/028669, attorney docketnumber 25791.194.02, filed on Aug. 11, 2005; (137) PCT patentapplication serial number PCT/US2005/028453, attorney docket number25791.371, filed on Aug. 11, 2005; (138) PCT patent application serialnumber PCT/US2005/028641, attorney docket number 25791.372, filed onAug. 11, 2005; (139) PCT patent application serial numberPCT/US2005/028819, attorney docket number 25791.373, filed on Aug. 11,2005; (140) PCT patent application serial number PCT/US2005/028446,attorney docket number 25791.374, filed on Aug. 11, 2005; (141) PCTpatent application serial number PCT/US2005/028642, attorney docketnumber 25791.375, filed on Aug. 11, 2005; (142) PCT patent applicationserial number PCT/US2005/028451, attorney docket number 25791.376, filedon Aug. 11, 2005, and (143). PCT patent application serial numberPCT/US2005/028473, attorney docket number 25791.377, filed on Aug. 11,2005, (144) U.S. utility patent application Ser. No. 10/546,082,attorney docket number 25791.378, filed on Aug. 16, 2005, (145) U.S.utility patent application Ser. No. 10/546,076, attorney docket number25791.379, filed on Aug. 16, 2005, (146) U.S. utility patent applicationSer. No. 10/545,936, attorney docket number 25791.380, filed on Aug. 16,2005, (147) U.S. utility patent application Ser. No. 10/546,079,attorney docket number 25791.381, filed on Aug. 16, 2005 (148) U.S.utility patent application Ser. No. 10/545,941, attorney docket number25791.382, filed on Aug. 16, 2005, (149) U.S. utility patent applicationSer. No. 546078, attorney docket number 25791.383, filed on Aug. 16,2005, filed on Aug. 11, 2005, (150) U.S. utility patent application Ser.No. 10/545,941, attorney docket number 25791.185.05, filed on Aug. 16,2005, (151) U.S. utility patent application Ser. No. 11/249,967,attorney docket number 25791.384, filed on Oct. 13, 2005, (152) U.S.provisional patent application Ser. No. 60/734,302, attorney docketnumber 25791.24, filed on Nov. 7, 2005, (153) U.S. provisional patentapplication Ser. No. 60/725,181, attorney docket number 25791.184, filedon Oct. 11, 2005, (154) PCT patent application serial numberPCT/US2005/023391, attorney docket number 25791.299.02 filed Jun. 29,2005 which claims priority from U.S. provisional patent application Ser.No. 60/585,370, attorney docket number 25791.299, filed on Jul. 2, 2004,(155) U.S. provisional patent application Ser. No. 60/721,579, attorneydocket number 25791.327, filed on Sep. 28, 2005, (156) U.S. provisionalpatent application Ser. No. 60/717,391, attorney docket number25791.214, filed on Sep. 15, 2005, (157) U.S. provisional patentapplication Ser. No. 60/702,935, attorney docket number 25791.133, filedon Jul. 27, 2005, (158) U.S. provisional patent application Ser. No.60/663,913, attorney docket number 25791.32, filed on Mar. 21, 2005,(159) U.S. provisional patent application Ser. No. 60/652,564, attorneydocket number 25791.348, filed on Feb. 14, 2005, (160) U.S. provisionalpatent application Ser. No. 60/645,840, attorney docket number25791.324, filed on Jan. 21, 2005, (161) PCT patent application serialnumber PCT/US2005/______, attorney docket number 25791.326.02, filed onNov. 29, 2005 which claims priority from U.S. provisional patentapplication Ser. No. 60/631,703, attorney docket number 25791.326, filedon Nov. 30, 2004, (162) U.S. provisional patent application Ser. No.______, attorney docket number 25791.339, filed on Dec. 22, 2005, (163)U.S. National Stage application Ser. No. 10/548,934, attorney docket no.25791.253.05, filed on Sep. 12, 2005; (164) U.S. National Stageapplication Ser. No. 10/549,410, attorney docket no. 25791.262.05, filedon Sep. 13, 2005; (165) U.S. Provisional Patent Application No.60/717,391, attorney docket no. 25791.214 filed on Sep. 15, 2005; (166)U.S. National Stage application Ser. No. 10/550,906, attorney docket no.25791.260.06, filed on Sep. 27, 2005; (167) U.S. National Stageapplication Ser. No. 10/551,880, attorney docket no. 25791.270.06, filedon Sep. 30, 2005; (168) U.S. National Stage application Ser. No.10/552,253, attorney docket no. 25791.273.06, filed on Oct. 4, 2005;(169) U.S. National Stage application Ser. No. 10/552,790, attorneydocket no. 25791.272.06, filed on Oct. 11, 2005; (170) U.S. ProvisionalPatent Application No. 60/725,181, attorney docket no. 25791.184 filedon Oct. 11, 2005; (171) U.S. National Stage application Ser. No.10/553,094, attorney docket no. 25791.193.03, filed on Oct. 13, 2005;(172) U.S. National Stage application Ser. No. 10/553,566, attorneydocket no. 25791.277.06, filed on Oct. 17, 2005; (173) PCT PatentApplication No. PCT/US2006/______, attorney docket no. 25791.324.02filed on Jan. 20, 2006, and (174) PCT Patent Application No.PCT/US2006/______, attorney docket no. 25791.348.02 filed on Feb. 9,2006; (175) U.S. Utility patent application Ser. No. ______, attorneydocket no. 25791.386, filed on Feb. 17, 2006, (176) U.S. National Stageapplication Ser. No. ______, attorney docket no. 25791.301.06, filed on______, (177) U.S. National Stage application Ser. No. ______, attorneydocket no. 25791.137.04, filed on ______, (178) U.S. National Stageapplication Ser. No. ______, attorney docket no. 25791.215.06, (179)U.S. National State patent application Ser. No. ______, attorney docketno. 25791.305.05, filed on ______; (180) U.S. National State patentapplication Ser. No. ______, attorney docket no. 25791.306.04, filed on______; (181) U.S. National State patent application Ser. No. ______,attorney docket no. 25791.307.04, filed on ______; and (182) U.S.National State patent application Ser. No. ______, attorney docket no.25791.308.07, filed on ______, the disclosures of which are incorporatedherein by reference.

Referring to FIG. 35 a an exemplary embodiment of an expandable tubularmember 3500 includes a first tubular region 3502 and a second tubularportion 3504. In an exemplary embodiment, the material properties of thefirst and second tubular regions, 3502 and 3504, are different. In anexemplary embodiment, the yield points of the first and second tubularregions, 3502 and 3504, are different. In an exemplary embodiment, theyield point of the first tubular region 3502 is less than the yieldpoint of the second tubular region 3504. In several exemplaryembodiments, one or more of the expandable tubular members, 12, 14, 24,26, 102, 104, 106, 108, 202 and/or 204 incorporate the tubular member3500.

Referring to FIG. 35 b, in an exemplary embodiment, the yield pointwithin the first and second tubular regions, 3502 a and 3502 b, of theexpandable tubular member 3502 vary as a function of the radial positionwithin the expandable tubular member. In an exemplary embodiment, theyield point increases as a function of the radial position within theexpandable tubular member 3502. In an exemplary embodiment, therelationship between the yield point and the radial position within theexpandable tubular member 3502 is a linear relationship. In an exemplaryembodiment, the relationship between the yield point and the radialposition within the expandable tubular member 3502 is a non-linearrelationship. In an exemplary embodiment, the yield point increases atdifferent rates within the first and second tubular regions, 3502 a and3502 b, as a function of the radial position within the expandabletubular member 3502. In an exemplary embodiment, the functionalrelationship, and value, of the yield points within the first and secondtubular regions, 3502 a and 3502 b, of the expandable tubular member3502 are modified by the radial expansion and plastic deformation of theexpandable tubular member.

In several exemplary embodiments, one or more of the expandable tubularmembers, 12, 14, 24, 26, 102, 104, 106, 108, 202, 204 and/or 3502, priorto a radial expansion and plastic deformation, include a microstructurethat is a combination of a hard phase, such as martensite, a soft phase,such as ferrite, and a transitionary phase, such as retained austentite.In this manner, the hard phase provides high strength, the soft phaseprovides ductility, and the transitionary phase transitions to a hardphase, such as martensite, during a radial expansion and plasticdeformation. Furthermore, in this manner, the yield point of the tubularmember increases as a result of the radial expansion and plasticdeformation. Further, in this manner, the tubular member is ductile,prior to the radial expansion and plastic deformation, therebyfacilitating the radial expansion and plastic deformation. In anexemplary embodiment, the composition of a dual-phase expandable tubularmember includes (weight percentages): about 0.1% C, 1.2% Mn, and 0.3%Si.

In an exemplary experimental embodiment, as illustrated in FIGS. 36 a-36c, one or more of the expandable tubular members, 12, 14, 24, 26, 102,104, 106, 108, 202, 204 and/or 3502 are processed in accordance with amethod 3600, in which, in step 3602, an expandable tubular member 3602 ais provided that is a steel alloy having following material composition(by weight percentage): 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si,0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti.In an exemplary experimental embodiment, the expandable tubular member3602 a provided in step 3602 has a yield strength of 45 ksi, and atensile strength of 69 ksi.

In an exemplary experimental embodiment, as illustrated in FIG. 36 b, instep 3602, the expandable tubular member 3602 a includes amicrostructure that includes martensite, pearlite, and V, Ni, and/or Ticarbides.

In an exemplary embodiment, the expandable tubular member 3602 a is thenheated at a temperature of 790° C. for about 10 minutes in step 3604.

In an exemplary embodiment, the expandable tubular member 3602 a is thenquenched in water in step 3606.

In an exemplary experimental embodiment, as illustrated in FIG. 36 c,following the completion of step 3606, the expandable tubular member3602 a includes a microstructure that includes new ferrite, grainpearlite, martensite, and ferrite. In an exemplary experimentalembodiment, following the completion of step 3606, the expandabletubular member 3602 a has a yield strength of 67 ksi, and a tensilestrength of 95 ksi.

In an exemplary embodiment, the expandable tubular member 3602 a is thenradially expanded and plastically deformed using one or more of themethods and apparatus described above. In an exemplary embodiment,following the radial expansion and plastic deformation of the expandabletubular member 3602 a, the yield strength of the expandable tubularmember is about 95 ksi.

In an exemplary experimental embodiment, as illustrated in FIGS. 37 a-37c, one or more of the expandable tubular members, 12, 14, 24, 26, 102,104, 106, 108, 202, 204 and/or 3502 are processed in accordance with amethod 3700, in which, in step 3702, an expandable tubular member 3702 ais provided that is a steel alloy having following material composition(by weight percentage): 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si,0.01% Cu, 0.01% Ni, 0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti.In an exemplary experimental embodiment, the expandable tubular member3702 a provided in step 3702 has a yield strength of 60 ksi, and atensile strength of 80 ksi.

In an exemplary experimental embodiment, as illustrated in FIG. 37 b, instep 3702, the expandable tubular member 3702 a includes amicrostructure that includes pearlite and pearlite striation.

In an exemplary embodiment, the expandable tubular member 3702 a is thenheated at a temperature of 790° C. for about 10 minutes in step 3704.

In an exemplary embodiment, the expandable tubular member 3702 a is thenquenched in water in step 3706.

In an exemplary experimental embodiment, as illustrated in FIG. 37 c,following the completion of step 3706, the expandable tubular member3702 a includes a microstructure that includes ferrite, martensite, andbainite. In an exemplary experimental embodiment, following thecompletion of step 3706, the expandable tubular member 3702 a has ayield strength of 82 ksi, and a tensile strength of 130 ksi.

In an exemplary embodiment, the expandable tubular member 3702 a is thenradially expanded and plastically deformed using one or more of themethods and apparatus described above. In an exemplary embodiment,following the radial expansion and plastic deformation of the expandabletubular member 3702 a, the yield strength of the expandable tubularmember is about 130 ksi.

In an exemplary experimental embodiment, as illustrated in FIGS. 38 a-38c, one or more of the expandable tubular members, 12, 14, 24, 26, 102,104, 106, 108, 202, 204 and/or 3502 are processed in accordance with amethod 3800, in which, in step 3802, an expandable tubular member 3802 ais provided that is a steel alloy having following material composition(by weight percentage): 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si,0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti.In an exemplary experimental embodiment, the expandable tubular member3802 a provided in step 3802 has a yield strength of 56 ksi, and atensile strength of 75 ksi.

In an exemplary experimental embodiment, as illustrated in FIG. 38 b, instep 3802, the expandable tubular member 3802 a includes amicrostructure that includes grain pearlite, widmanstatten martensiteand carbides of V, Ni, and/or Ti.

In an exemplary embodiment, the expandable tubular member 3802 a is thenheated at a temperature of 790° C. for about 10 minutes in step 3804.

In an exemplary embodiment, the expandable tubular member 3802 a is thenquenched in water in step 3806.

In an exemplary experimental embodiment, as illustrated in FIG. 38 c,following the completion of step 3806, the expandable tubular member3802 a includes a microstructure that includes bainite, pearlite, andnew ferrite. In an exemplary experimental embodiment, following thecompletion of step 3806, the expandable tubular member 3802 a has ayield strength of 60 ksi, and a tensile strength of 97 ksi.

In an exemplary embodiment, the expandable tubular member 3802 a is thenradially expanded and plastically deformed using one or more of themethods and apparatus described above. In an exemplary embodiment,following the radial expansion and plastic deformation of the expandabletubular member 3802 a, the yield strength of the expandable tubularmember is about 97 ksi.

In several exemplary embodiments, the teachings of the presentdisclosure are combined with one or more of the teachings disclosed inFR 2 841 626, filed on Jun. 28, 2002, and published on Jan. 2, 2004, thedisclosure of which is incorporated herein by reference.

Referring now to FIGS. 39 a, 39 b, 39 c, and 39 d, in an exemplaryembodiment, an expansion device 3900 for radially expanding andplastically deforming a tubular member includes a base member 3902 thatdefines a centrally positioned longitudinal passage 3902 a and includesan external flange 3902 b, an external flange 3902 c, a tapered externalconical flange 3902 d, and an external flange 3902 e adjacent the end ofthe conical flange 3902 d. A pair of radial passages, 3902 f and 3902 g,defined by the base member 3902 are positioned on opposite sides offlange 3902 b, extending from the passage 3902 a and through the basemember 3902, and each include respective flow control valves, 3902 faand 3902 ga, respectively, operable to open and close their respectiveradial passages. A tubular housing 3904 defines a centrally positionedlongitudinal passage 3904 a that receives and mates with base member3902 and defines an internal annular recess 3904 b that receives andmates with the external flange 3902 b of the base member 3902. A pair ofpassages. 3904 c and 3904 d, defined by the tubular housing 3904 arepositioned on opposite sides of the tubular housing 3904 and extendthrough the tubular housing 3904, with each including respective flowcontrol valves, 3904 ca and 3904 da, respectively, operable to open andclose their respective passages. A plurality of circumferentially spacedapart mounting members 3904 e are coupled to an end face of the tubularhousing 3904. The ends of a plurality of links 3906 are pivotablycoupled to corresponding mounting members 3904 e on tubular housing3904. The ends of a plurality of expansion segments 3908 are pivotablycoupled to the other ends of corresponding links 3906 and are mountedupon, supported by, and circumferentially distributed about thecircumference of the tapered external conical flange 3902 d of the basemember 3902. In an exemplary embodiment, the other ends of the expansionsegments 3908 include a channel 3908 a and a tooth 3908 b adjacent thechannel 3908 a and extending from the expansion segment 3908 in acircumferential direction and into the channel 3908 a of the adjacentexpansion segment 3908, resulting in adjacent expansion segments 3908overlapping each other in the circumferential direction.

In an exemplary embodiment, the external surface of the expansionsegments 3908 may be, for example, linear, non-linear, hyperbolic, or avariety of other shapes known in the art. In an exemplary embodiment,materials used for components of the expansion device 3900 have highhardness, high compressive strength, high wear resistance, highcorrosion resistance, and high toughness. In an exemplary embodiment,materials used for components of the expansion device 3900 include highchrome based tools steels, high carbon base tool steels, and molybdenumbased tool steels such as, for example, DC53 tool steels, D2 toolsteels, D3 tool steels, D5 tool steels, D7 tool steels, M2 tool steels,M4 tool steels, CPM M4 tool steels, 10V tool steels and 3V tool steels.In an exemplary embodiment, the working surfaces of the components ofexpansion device 3900 are hard and wear resistant and coated by methodssuch as, for example, chemical vapor deposition and physical vapordeposition.

Referring now to FIGS. 39 a, 39 b, 39 c, 39 d, 40 a, 40 b and 40 c, inan exemplary embodiment, in operation, expansion device 3900 beginsoperation with expansion segments 3908 abutting flange 3902 c with thetooth 3908 b on each expansion segment 3908 extending into the channel3908 a on an adjacent expansion segment 3908, resulting in the expansionsegments 3908 overlapping each other in the circumferential direction.In an exemplary embodiment, an end of the expansion device 3900 iscoupled to a tubular coupling 3910 such as, for example, a drill stringor other tubular members known in the art, which may provide a hydraulicfluid to the centrally positioned longitudinal passage 3902 a. Theexpansion device 3900 may then be expanded by opening flow control valve3902 fa in radial passage 3902 f and opening flow control valve 3904 dain passage 3904 d, and closing flow control valve 3904 ca in passage3904 c and closing flow control valve 3902 ga in radial passage 3902 g,allowing hydraulic fluid to enter and exit internal annular recess 3904b on opposite sides of the external flange 3902 b, resulting in apressure differential across external flange 3902 b that causes thetubular housing 3904 to translate in a direction A₁ along the basemember 3902. Translation of the tubular housing 3904 in direction A₁causes the expansion segments 3908 to translate along the surface oftapered external conical flange 3902 d through the pivotal coupling ofthe expansion segments 3908 and the tubular housing 3904 by links 3906.During the translation of the expansion segments 3908 along the taperedexternal conical flange 3902 d, the tooth 3908 b on each expansionsegment 3908 translates in a circumferential direction through channel3908 a on the adjacent expansion segment 3908, but remains in thechannel 3908 a, resulting in the expansion segments 3908 continuing tooverlap each other in the circumferential direction throughout theirtranslation along the surface of tapered external conical flange 3902 d.

In an exemplary embodiment, the expansion segments 3908 may be retractedby opening flow control valve 3902 ga in radial passage 3902 g and flowcontrol valve 3904 ca in passage 3904 c, respectively, and closing flowcontrol valve 3902 fa in radial passage 3902 f and flow control valve3904 da in passage 3904 d, respectively, allowing hydraulic fluid toenter and exit internal annular recess 3904 b on opposite sides of theexternal flange 3902 b, resulting in a pressure differential acrossexternal flange 3902 b that causes the tubular housing 3904 to translatein a direction A₂ along the base member 3902, bringing expansionsegments 3908 back into abutment with flange 3902 c.

In an exemplary embodiment, upon expansion, the expansion segments 3908may separate from each other in a circumferential direction along aportion of their length while still overlapping each other in thecircumferential direction at their ends. In an exemplary embodiment, theoverlapping relationship between the expansion segments 3908 preventsaxial grooves, or other surface defects, from forming on an innersurface of a tubular member when the expansion device 3900 is displacedaxially through that tubular member.

In an exemplary embodiment, the expansion segments 3908, the flanges3902 c and 3902 e, and the tapered external conical flange 3902 dprovide an adjustable expansion assembly 3912. In an exemplaryembodiment, the tubular housing 3904, centrally positioned longitudinalpassage 3904 a, internal annular recess 3904 b, external flange 3902 b,passages 3902 f, 3902 g, 3904 c and 3904 d, and flow control valves 3902fa, 3902 ga, 3904 ca and 3904 da, provide an actuator 3914. In anexemplary embodiment, actuator 3914 may be a conventional actuator knownin the art such as, for example, a hydraulic actuator, an electricalactuator, a mechanical actuator, or a combination thereof. In anexemplary embodiment, the expansion device 3900 may be a conventionaladjustable expansion device and/or expansion device 20, 114, 210, 2234,2334, 2434, 2534, 2634, 2734, or 3134.

Referring now to FIG. 41, an alternative embodiment of an expansionsystem 4000 for expanding a tubular member is substantially identical indesign and operation to expansion device 3900 described above withreference to FIGS. 39 a, 39 b, 39 c, 39 d, 40 a, 40 b and 40 c with theaddition of a tubular member 4002. Tubular member 4002 includes an outersurface 4002 a, an inner surface 4002 b with an inner diameter D_(t), awall thickness 4002 c, and defines a passage 4002 d extending throughthe tubular member 4002.

Referring now to FIGS. 39 a, 39 c, 39 d, 40 a, 40 c, 42 a and 42 b, inan exemplary embodiment, in operation, expansion device 3900 ispositioned in passage 4002 d defined by tubular member 4002. Expansiondevice 3900 begins operation with expansion segments 3908 abuttingflange 3902 c with the tooth 3908 b on each expansion segment 3908extending into the channel 3908 a on an adjacent expansion segment 3908,resulting in the expansion segments 3908 overlapping each other in thecircumferential direction. In an exemplary embodiment, the expansiondevice 3900 is coupled to a tubular coupling 3910 such as, for example,a drill string or other tubular members known in the art, which mayprovide a hydraulic fluid to the centrally positioned longitudinalpassage 3902 a. In an exemplary embodiment, the expansion segments 3908have a diameter D₁ which is greater than the inner diameter D_(t) of thetubular member 4002, which causes the tubular member 4002 to radiallyexpand and, due to the overlapping relationship of the expansionsegments 3908, is sufficient to allow a pressure drop across theexpansion device 3900 to overcome the forces necessary to expand thetubular member 4002 when hydraulic fluid is provided behind theexpansion device 3900. In an exemplary embodiment, the percentageincrease of tubular member 4002 from inner diameter D_(t) to diameter D₁is greater than or equal to 1% of the total desired expansion percentagefor the tubular member 4002. In an exemplary embodiment, diameter D₁ isless than or equal to inner diameter D_(t), and a convention sealingmethod known in the art is used to allow a pressure drop across theexpansion device 3900 in order to overcome the forces necessary toexpand the tubular member 4002 when hydraulic fluid is provided behindthe expansion device 3900. The expansion device 3900 may then beexpanded by opening flow control valve 3902 fa in radial passage 3902 fand opening flow control valve 3904 da in passage 3904 d, and closingflow control valve 3904 ca in passage 3904 c and closing flow controlvalve 3902 ga in radial passage 3902 g, allowing hydraulic fluid toenter and exit internal annular recess 3904 b on opposite sides of theexternal flange 3902 b, resulting in a pressure differential acrossexternal flange 3902 b that causes the tubular housing 3904 to translatein a direction B₁ along the base member 3902. Translation of the tubularhousing 3904 in direction B₁ causes the expansion segments 3908 totranslate along the surface of tapered external conical flange 3902 dthrough the pivotal coupling of the expansion segments 3908 and thetubular housing 3904 by links 3906. During the translation of theexpansion segments 3908 along the tapered external conical flange 3902d, the tooth 3908 b on each expansion segment 3908 translates in acircumferential direction through channel 3908 a on the adjacentexpansion segment 3908, but remains in the channel 3908 a, resulting inthe expansion segments 3908 continuing to overlap each other throughouttheir translation along the surface of tapered external conical flange3902 d. Upon expansion, the expansion segments 3908 have a diameter D₂which is greater than the diameter D_(t) of the tubular member 4002,which causes the tubular member 4002 to radially expand and plasticallydeform and, due to the overlapping relationship of the expansionsegments 3908, is sufficient to allow a pressure drop across theexpansion device 3900 to overcome the forces necessary to expand thetubular member 4002 when hydraulic fluid is provided behind theexpansion device 3900.

In an exemplary embodiment, hydraulic fluid may then be provided throughthe centrally located longitudinal passage 3902 a to create a pressuredrop across the adjustable expansion assembly 3912 sufficient toovercome the force necessary to radially expand and plastically deformthe tubular member 4002, displacing the expansion device 3900 axiallythrough the tubular member 4002 in a direction B₂. Furthermore, inseveral exemplary embodiments, the expansion device 3900 may bedisplaced, including translation and/or rotation, relative to thetubular member 4002 using a variety of conventional methods known in theart.

In an exemplary embodiment, before, during, or after the relativedisplacement of the expansion device 3900 through the tubular member4002, the expansion segments 3908 may be retracted by opening flowcontrol valve 3902 ga in radial passage 3902 g and opening flow controlvalve 3904 ca in passage 3904 c, and closing flow control valve 3902 fain radial passage 3902 f and closing flow control valve 3904 da inpassage 3904 d, allowing hydraulic fluid to enter and exit internalannular recess 3904 b on opposite sides of the external flange 3902 b,resulting in a pressure differential across external flange 3902 b thatcauses the tubular housing 3904 to translate in direction B₂ along thebase member 3902, bringing expansion segments 3908 back into abutmentwith flange 3902 c.

In an exemplary embodiment, the tubular member 4002 may be, for example,tubular member 12, 14, 24, 26, 102, 108, 202, 204, 2210, 2228, 2310,2328, 2410, 2428, 2510, 2528, 2610, 2628, 2710, 2728, 2910, 2926, 3010,3024, 3030, 3044, 3050, 3068, 3110, 3124, 3210, 3220, 3310, 3330, 3410,3432, or 3500, or a tubular assembly such as, for example, tubularassembly 10, 22, 100, or 200. In an exemplary embodiment, uponexpansion, the expansion segments 3908 may separate from each other in acircumferential direction along a portion of their length while stilloverlapping each other in the circumferential direction at their ends,and using a conventional lubrication system known in the art, alubricant may be injected between the expansion segments 3908 and theinner surface 4002 b of tubular member 4002 to provide lubricationbetween the adjustable expansion assembly 3912 and the tubular member4002.

Referring now to FIGS. 43 a and 43 b, an alternative embodiment of anexpansion device 4100 for expanding a tubular member is substantiallyidentical in design and operation to expansion device 3900 describedabove with reference to FIGS. 39 a, 39 b, 39 c, 39 d, 40 a, 40 b and 40c with the addition of a tapered conical preliminary expansion member4102 and a lubrication system 4104. Preliminary expansion member 4102 iscoupled to base member 3902 adjacent actuator 3914. A lubrication system4104 is coupled to the base member 3902 adjacent the preliminaryexpansion member 4102 and includes a plurality of lubrication vents 4104a open to the surface of preliminary expansion member 4102. Thelubrication vents 4104 a are coupled to a lubrication reservoir 4104 bwhich includes a piston 4104 c and a piston actuator 4104 d. In anexemplary embodiment, the lubrication system 4104 may be a conventionalcommercially available lubrication system, and/or one or more of thelubrication systems described in PCT patent application serial numberPCT/US2004/028888, attorney docket number 25791.305.02, filed on Sep. 7,2004, which is herein incorporated by reference. In an exemplaryembodiment, the lubrication system 4104 may be a convention commerciallyavailable lubrication system, and/or the lubrication system described inPCT patent application serial number PCT/US2004/028889, attorney docketnumber 25791.307.02, filed on Sep. 7, 2004, which is herein incorporatedby reference.

Referring now to FIGS. 43 a, 43 b and 43 c, in an exemplary embodiment,in operation, expansion device 4100 begins operation with expansionsegments 3908 abutting flange 3902 c and overlapping each other in thecircumferential direction. In an exemplary embodiment, the expansiondevice 4100 is coupled to a tubular coupling 3910 such as, for example,a drill string or other tubular members known in the art, which mayprovide a hydraulic fluid to the centrally positioned longitudinalpassage 3902 a. The expansion device 4100 may then be expanded byopening flow control valve 3902 fa in radial passage 3902 f and openingflow control valve 3904 da in passage 3904 d, and closing flow controlvalve 3904 ca in passage 3904 c and closing flow control valve 3902 gain radial passage 3902 g, allowing hydraulic fluid to enter and exitinternal annular recess 3904 b on opposite sides of the external flange3902 b, resulting in a pressure differential across external flange 3902b that causes the tubular housing 3904 to translate in a direction C,along the base member 3902. Translation of the tubular housing 3904 indirection C, causes the expansion segments 3908 to translate along thesurface of tapered external conical flange 3902 d through the pivotalcoupling of the expansion segments 3908 and the tubular housing 3904 bylinks 3906. During the translation of the expansion segments 3908 alongthe tapered external conical flange 3902 d, the expansion segments 3908continue to overlap each other in the circumferential directionthroughout their translation.

In an exemplary embodiment, the expansion segments 3908 may be retractedby opening flow control valve 3902 ga in radial passage 3902 g andopening flow control valve 3904 ca in passage 3904 c, and closing flowcontrol valve 3902 fa in radial passage 3902 f and closing flow controlvalve 3904 da in passage 3904 d, allowing hydraulic fluid to enter andexit internal annular recess 3904 b on opposite sides of the externalflange 3902 b, resulting in a pressure differential across externalflange 3902 b that causes the tubular housing 3904 to translate in adirection C₂ along the base member 3902, bringing expansion segments3908 back into abutment with flange 3902 c.

In an exemplary embodiment, upon expansion, the expansion segments 3908may separate from each other in a circumferential direction along aportion of their length while still overlapping each other in thecircumferential direction at their ends. In an exemplary embodiment, theexpansion device 4100 may be a conventional adjustable expansion deviceand/or expansion device 20, 114, 210, 2234, 2334, 2434, 2534, 2634,2734, or 3134.

Referring now to FIGS. 41, 44 a and 44 b, an alternative embodiment ofan expansion system 4200 for expanding a tubular member is substantiallyidentical in design and operation to expansion device 4100 describedabove with reference to FIGS. 43 a and 43 b with the addition of tubularmember 4002 which includes an outer surface 4002 a, an inner surface4002 b with an inner diameter D_(t), a thickness 4002 c, and defines apassageway 4002 d extending through the tubular member 4002.

Referring now to FIGS. 39 a, 39 b, 39 c, 39 d, 40 a, 40 b, 40 c, 44 a,and 44 b, in an exemplary embodiment, in operation, the expansion device4100 is positioned in the passage 4002 d defined by tubular member 4002.The expansion device 4100 begins operation with expansion segments 3908abutting flange 3902 c and overlapping each other in the circumferentialdirection. The preliminary expansion member 4102 has a diameter D₃ whichis greater than the inner diameter D_(t) of the tubular member 4002,which causes the tubular member 4002 to radially expand and issufficient to allow a pressure drop across the expansion device 4100 toovercome the forces necessary to expand the tubular member 4002 whenhydraulic fluid is provided behind the expansion device 4100. In anexemplary embodiment, the percentage increase of tubular member 4002from inner diameter D_(t) to diameter D₃ is greater than or equal to 1%of the total desired expansion percentage for the tubular member 4002.In an exemplary embodiment, the expansion device 4100 is coupled to atubular coupling 3910 such as, for example, a drill string or othertubular members known in the art, which may provide a hydraulic fluid tothe centrally positioned longitudinal passage 3902 a. The expansiondevice 4100 may then be expanded by opening flow control valve 3902 fain radial passage 3902 f and opening flow control valve 3904 da inpassage 3904 d, and closing flow control valve 3904 ca in passage 3904 cand closing flow control valve 3902 ga in radial passage 3902 g,allowing hydraulic fluid to enter and exit internal annular recess 3904b on opposite sides of the external flange 3902 b, resulting in apressure differential across external flange 3902 b that causes thetubular housing 3904 to translate in a direction D₁ along the basemember 3902. Translation of the tubular housing 3904 in direction D₁causes the expansion segments 3908 to translate along the surface oftapered external conical flange 3902 d through the pivotal coupling ofthe expansion segments 3908 and the tubular housing 3904 by links 3906.During the translation of the expansion segments 3908 along the taperedexternal conical flange 3902 d, the expansion segments 3908 continue tooverlap each other in the circumferential direction throughout theirtranslation. Upon expansion, the expansion segments 3908 have a diameterD₄ which is greater than the diameter D_(t) of the tubular member 4002,which causes the tubular member 4002 to radially expand and plasticallydeform.

In an exemplary embodiment, hydraulic fluid may then be provided throughthe centrally located longitudinal passage 3902 a to create a pressuredrop across the preliminary expansion member 4102 sufficient to overcomethe force necessary to radially expand and plastically deform thetubular member 4002, displacing the expansion device 4100 axiallythrough the tubular member 4002 in a direction D₂. Furthermore, inseveral exemplary embodiments, the expansion device 4100 may bedisplaced, including translation and/or rotation, relative to thetubular member 4002 using a variety of conventional methods known in theart.

In an exemplary embodiment, lubrication may be provided between thepreliminary expansion member 4102 and the tubular member 4002 byactuating the piston actuators 4104 d to decrease the volume of thelubrication reservoir 4104 b and provide lubrication through thelubrication vents 4104 a.

In an exemplary embodiment, before, during, or after the relativedisplacement of the expansion device 4100 through the tubular member4002, the expansion segments 3908 may be retracted by opening flowcontrol valve 3902 ga in radial passage 3902 g and opening flow controlvalve 3904 ca in passage 3904 c, and closing flow control valve 3902 fain radial passage 3902 f and closing flow control valve 3904 da inpassage 3904 d, allowing hydraulic fluid to enter and exit internalannular recess 3904 b on opposite sides of the external flange 3902 b,resulting in a pressure differential across external flange 3902 b thatcauses the tubular housing 3904 to translate in direction D₂ along thebase member 3902, bringing expansion segments 3908 back into abutmentwith flange 3902 c. In an exemplary embodiment, the tubular member 4002may be, for example, tubular member 12, 14, 24, 26, 102, 108, 202, 204,2210, 2228, 2310, 2328, 2410, 2428, 2510, 2528, 2610, 2628, 2710, 2728,2910, 2926, 3010, 3024, 3030, 3044, 3050, 3068, 3110, 3124, 3210, 3220,3310, 3330, 3410, 3432, or 3500, or a tubular assembly such as, forexample, tubular assembly 10, 22, 100, or 200.

Referring now to FIG. 45 a, an alternative embodiment of an expansiondevice 4300 for expanding a tubular member is substantially identical indesign and operation to expansion devices 3900 and 4100 described abovewith reference to FIGS. 39 a, 39 b, 39 c, 39 d, 40 a, 40 b, 40 c, 43 a,43 b, and 43 c with the addition of a actuator 4302 replacing theactuator 3914. Actuator 4302 includes tubular housing 4302 a defining acentrally positioned longitudinal passage 4302 b that receives and mateswith base member 3902 and defining an internal annular recess 4302 c. Anannular threaded section 4302 d extends from tubular housing 4302 a,into internal annular recess 4302 c, and into engagement with a radialthreaded section 4302 e extending from the base member 3902. Arotational actuator 4302 f is coupled to the base member 3902 and thebase member 3902 includes a rotational coupling 4302 g which allows thesection of base member 3902 including radial threaded section 4302 e torotate relative to the section of base member 3902 including taperedexternal conical flange 3902 d.

Referring now to FIGS. 39 a, 40 a, 45 a, 45 b, and 45 c, in an exemplaryembodiment, in operation, expansion device 4300 begins operation withexpansion segments 3908 abutting flange 3902 c with the expansionsegments 3908 overlapping each other in the circumferential direction.In an exemplary embodiment, the expansion device 4300 is coupled to atubular coupling 3910 such as, for example, a drill string or othertubular members known in the art, which may provide a hydraulic fluid tothe centrally positioned longitudinal passage 3902 a. The expansiondevice 4300 may then be expanded by actuating the actuator 4302 f androtating the base 3902 which, due to the interaction of annular threadedsection 4302 d and radial threaded section 4302 e, causes the tubularhousing 3904 to translate in a direction E₁ along the base member 3902.Translation of the tubular housing 3904 in direction E₁ causes theexpansion segments 3908 to translate along the surface of taperedexternal conical flange 3902 d through the pivotal coupling of theexpansion segments 3908 and the tubular housing 3904 by links 3906.During the translation of the expansion segments 3908 along the taperedexternal conical flange 3902 d, the expansion segments 3908 continuingto overlap each other in the circumferential direction throughout theirtranslation along the surface of tapered external conical flange 3902 d.

In an exemplary embodiment, actuator 4302 may be locked in place at anintermediate location along the tapered external conical member 3902 d,as illustrated in FIG. 45 b, securing expansion segments 3908 in anintermediate position along tapered external conical flange 3902 d. Inan exemplary embodiment, the expansion segments 3908 may be actuatedinto engagement with the flange 3902 e.

In an exemplary embodiment, the expansion segments 3908 may be retractedby actuating the actuator 4302 f and rotating the base 3902 which, dueto the interaction of annular threaded section 4302 d and radialthreaded section 4302 e, causes the tubular housing 3904 to translate ina direction E₂ along the base member 3902, causing the tubular housing3904 to translate along the base member 3902, bringing expansionsegments 3908 back into abutment with flange 3902 c. In an exemplaryembodiment, upon expansion, the expansion segments 3908 may separatefrom each other in a circumferential direction along a portion of theirlength while still overlapping each other in the circumferentialdirection at their ends. In an exemplary embodiment, the expansiondevice 3900 may be a conventional adjustable expansion device and/orexpansion device 20, 114, 210, 2234, 2334, 2434, 2534, 2634, 2734, or3134.

In an exemplary embodiment, the expansion device 4300 may be operated asdescribed above with reference to expansion devices 3900 and 4100 andexpansion systems 4000 and 4200, illustrated in FIGS. 39 a, 39 b, 39 c,39 d, 40 a, 40 b, 40 c, 41, 42 a, 42 b, 43 a, 43 b, 43 c, 44 a, and 44b.

Referring now to FIG. 46, an alternative embodiment of an expansiondevice 4400 for expanding a tubular member is substantially identical indesign and operation to expansion device 3900 described above withreference to FIGS. 39 a, 39 b, 39 c, 39 d, 40 a, 40 b and 40 c with theaddition of a actuator 4402 coupled to the base member 3902 adjacent theactuator 3914 and a cylindrical support member 4404 coupled to the basemember 3902 adjacent the translating member 4402. The actuator 4402includes a conventional actuator and, in an exemplary embodiment, maybe, for example, a hydraulic actuator, a mechanical actuator, anelectrical actuator, or combinations thereof. The cylindrical supportmember 4404 is flexibly coupled to the translating member 4402 bycouplings 4404 a and 4404 b and defines a centrally located longitudinalpassage 4404 c for mating with the base member 3092 and includes aplurality of securing members 4404 d about its circumference. A radialpassage 4406 is defined by the base member 3902 and includes a flowcontrol valve 4406 a for opening and closing the radial passage 4406.

Referring now to FIGS. 39 a, 39 b, 39 c, 39 d, 40 a, 40 b, 40 c, 41, 47a, 47 b, and 47 c, in an exemplary embodiment, in operation, theexpansion device 4400 is positioned in the passageway 4002 d defined bytubular member 4002. Expansion device 4400 begins operation withexpansion segments 3908 abutting flange 3902 c and overlapping eachother in the circumferential direction. In an exemplary embodiment, theexpansion device 4400 is coupled to a tubular coupling 3910 such as, forexample, a drill string or other tubular members known in the art, whichmay provide a hydraulic fluid to the centrally positioned longitudinalpassage 3902 a. The expansion device 4400 may then be expanded byopening flow control valve 3902 fa in radial passage 3902 f and openingflow control valve 3904 da in passage 3904 d, and closing flow controlvalve 3904 ca in passage 3904 c and closing flow control valve 3902 gain radial passage 3902 g, allowing hydraulic fluid to enter and exitinternal annular recess 3904 b on opposite sides of the external flange3902 b, resulting in a pressure differential across external flange 3902b that causes the tubular housing 3904 to translate in a direction F₁along the base member 3902. Translation of the tubular housing 3904 indirection F₁ causes the expansion segments 3908 to translate along thesurface of tapered external conical flange 3902 d through the pivotalcoupling of the expansion segments 3908 and the tubular housing 3904 bylinks 3906. During the translation of the expansion segments 3908 alongthe tapered external conical flange 3902 d, the expansion segments 3908continue to overlap each other throughout their translation along thesurface of tapered external conical flange 3902 d. Upon expansion, theexpansion segments 3908 have a diameter D₅ which is greater than thediameter D_(t) of the tubular member 4002, which causes the tubularmember 4002 to radially expand and plastically deform.

In an exemplary embodiment, the expansion device 4400 may then bedisplaced axially through the tubular member 4002, radially expandingand plastically deforming the tubular member 4002 along its length, byfirst opening the flow control valve 4406 a in passage 4406 and allowinghydraulic fluid to create a pressure differential across cylindricalsupport member 4404, displacing the cylindrical support member 4404through the tubular member 4002 in a direction F₂ and extendingcouplings 4404 a and 4404 b. The securing members 4404 d on cylindricalsupport member 4404 may then be activated, securing the cylindricalsupport member 4404 to the inner surface 4002 b of tubular member 4002.With the cylindrical support member 4404 secured in the tubular member4002, the actuator 4402 may then be actuated, which displaces theexpansion device 4400 in a direction F₂ towards the cylindrical supportmember 4404 and axially through the tubular member 4002 usingcylindrical support member 4404 as a support, radially expanding andplastically deforming the tubular member 4002 from diameter D_(t) todiameter D₅. In an exemplary embodiment, spacing between the securingmembers 4404 d allows the hydraulic fluid to escape as the actuator 4402translates through the tubular member 4002. When cylindrical translatingactuator 4402 is positioned adjacent to cylindrical support member 4404,as illustrated in FIG. 47 c, the securing members 4404 d on cylindricalsupport member 4404 may be activated to release from the inner surface4002 b the tubular member 4002. The process described above may then berepeated in order to move the expansion device 4400 in direction F₂axially through the tubular member 4002 in order to radially expand andplastically deform the tubular member 4002 from diameter D_(t) todiameter D₅.

One of the problems of the pipe material selection for expandabletubular application is an apparent contradiction or inconsistencybetween strength and elongation. To increase burst and collapsestrength, material with higher yield strength is used. The higher yieldstrength generally corresponds to a decrease in the fracture toughnessand correspondingly limits the extent of achievable expansion.

It is desirable to select the steel material for the tubing by balancingsteel strength with amount absorbed energy measure by Charpy testing.Generally these tests are done on samples cut from tubular members. Ithas been found to be beneficial to cut directional samples bothlongitudinally oriented (aligned with the axis) and circumferentiallyoriented (generally perpendicular to the axis). This method of selectingsamples is beneficial when both directional orientations are used yetdoes not completely evaluate possible and characteristic anisotropythroughout a tubular member. Moreover, for small diameter tubing samplesrepresentative of the circumferential direction may be difficult andsometimes impossible to obtain because of the significant curvature ofthe tubing.

To further facilitate evaluation of a tubular member for suitability forexpansion it has been found beneficial according to one aspect of theinvention to consider the plastic strain ratio. One such ratio is calleda Lankford value (or r-value) which is the ratio of the strainsoccurring in the width and thickness directions measured in a singletension test. The plastic strain ratio (r or Lankford-value) with avalue of greater than 1.0 is found to be more resistant to thinning andbetter suited to tubular expansion. Such a Lankford value is found to bea measure of plastic anisotropy. The Lankford value (r) may becalculated by the Equation 2 below: $\begin{matrix}{r = \frac{\ln\frac{b_{o}}{b_{k}}}{\ln\frac{L_{k}b_{k}}{l_{o}b_{o}}}} & {{Equation}\quad 2}\end{matrix}$where,r—normal anisotropy coefficientb_(o), & b_(k)—initial and final widthL_(o) & L_(k)—initial and final length

However, it is time consuming and labor intensive for this parameter tobe measured using samples cut from real parts such as from the tubularmembers. The tubular members will have anisotropic characteristics dueto crystallographic or “grain” orientation and mechanically induceddifferences such as impurities, inclusions, and voids, requiringmultiple samples for reliably complete information. Moreover, withindividual samples, only local characteristics are determined and thecomplete anisotropy of the tubular member may not be determinable.Further some of the tubular members have small diameters so that cuttingsamples oriented in a circumferential direction is not always possible.Information regarding the characteristics in the circumferentialdirection has been found to be important because the plastic deformationduring expansion of the tubular members occurs to a very large extent inthe circumferential direction,

One aspect of the present exemplary embodiments comprises thedevelopment of an improved solution for anisotropy evaluation, includinga kind of plastic strain ratio similar to the Lankford parameter that ismeasured using real tubular members subjected to axial loading.

FIG. 48 depicts in a schematic fragmentary cross-sectional view along aplane along and through the axis 482 of a tubular member 480 that istested with axial opposed forces 484 and 485. The tubular member 480 isaxially stretched beyond the elastic limit, through yielding and toultimate yield or fracture. Measurements of the force and the OD and IDduring the process produce test data that can be used in the formulabelow to produce an expandability coefficient “f” as set forth inEquation 1 above. Alternatively a coefficient called a formabilityanisotropy coefficient F(r) that is function of the normal anisotropyLankford coefficient r may be determined as in Equation 3 below:$\begin{matrix}{{F(r)} = \frac{\ln\frac{b_{o}}{b_{k}}}{\ln\frac{L_{k}b_{k}}{l_{o}b_{o}}}} & {{Equation}\quad 3}\end{matrix}$F(r)—formability anisotropy coefficientb_(o) & b_(k)—initial and final tube area (inch²)L_(o) & L_(k)—initial and final tube length (inch)b=(D²−d²)/4—cross section tube area.

In either circumstance, f or F(r), the use of this testing method for anentire tubular member provides useful information including anisotropiccharacteristics or anisotropy of the tubular member for selecting orproducing beneficial tubular members for down hole expansion, similar tothe use of the Lankford value for a sheet material.

Just as values for stress and strain may be plotted for solid specimensamples, as schematically depicted in FIG. 49, the values for conductinga test on the tubular member may also be plotted, as depicted in FIG.50. On this basis the expansion coefficient f (or the formabilitycoefficient F(r)) may be determined. It will be the best to measuredistribution (Tensile-elongation) in longitudinal and circumferentialdirections simultaneously.

The foregoing expandability coefficient (or formability coefficient) isfound to be useful in predicting good expansion results and may befurther useful when used in combination with one or more otherproperties of a tubular member selected from stress-strain properties inone or more directional orientations of the material, strength &elongation, Charpy V-notch impact value in one or more directionalorientations of the material, stress burst rupture, stress collapserupture, yield strength, ductility, toughness, and strain-hardeningexponent (n-value), and hardness.

In an exemplary embodiment, a tribological system is used to reducefriction and thereby minimize the expansion forces required during theradial expansion and plastic deformation of the tubular members thatincludes one or more of the following: (1) a tubular tribology system;(2) a drilling mud tribology system; (3) a lubrication tribology system;and (4) an expansion device tribology system.

In an exemplary embodiment, the tubular tribology system includes theapplication of coatings of lubricant to the interior surface of thetubular members.

In an exemplary embodiment, the drilling mud tribology system includesthe addition of lubricating additives to the drilling mud.

In an exemplary embodiment, the lubrication tribology system includesthe use of lubricating greases, self-lubricating expansion devices,automated injection/delivery of lubricating greases into the interfacebetween an expansion device and the tubular members, surfaces within theinterface between the expansion device and the expandable tubular memberthat are self-lubricating, surfaces within the interface between theexpansion device and the expandable tubular member that are textured,self-lubricating surfaces within the interface between the expansiondevice and the expandable tubular member that include diamond and/orceramic inserts, thermosprayed coatings, fluoropolymer coatings, PVDfilms, and/or CVD films.

In an exemplary embodiment, the tubular members include one or more ofthe following characteristics: high burst and collapse, the ability tobe radially expanded more than about 40%, high fracture toughness,defect tolerance, strain recovery @ 150 F, good bending fatigue, optimalresidual stresses, and corrosion resistance to H₂S in order to provideoptimal characteristics during and after radial expansion and plasticdeformation.

In an exemplary embodiment, the tubular members are fabricated from asteel alloy having a charpy energy of at least about 90 ft-lbs in orderto provided enhanced characteristics during and after radial expansionand plastic deformation of the expandable tubular member.

In an exemplary embodiment, the tubular members are fabricated from asteel alloy having a weight percentage of carbon of less than about0.08% in order to provide enhanced characteristics during and afterradial expansion and plastic deformation of the tubular members.

In an exemplary embodiment, the tubular members are fabricated from asteel alloy having reduced sulfur content in order to minimize hydrogeninduced cracking.

In an exemplary embodiment, the tubular members are fabricated from asteel alloy having a weight percentage of carbon of less than about0.20% and a charpy-V-notch impact toughness of at least about 6 joulesin order to provide enhanced characteristics during and after radialexpansion and plastic deformation of the tubular members.

In an exemplary embodiment, the tubular members are fabricated from asteel alloy having a low weight percentage of carbon in order to enhancetoughness, ductility, weldability, shelf energy, and hydrogen inducedcracking resistance.

In several exemplary embodiments, the tubular members are fabricatedfrom a steel alloy having the following percentage compositions in orderto provide enhanced characteristics during and after radial expansionand plastic deformation of the tubular members: C Si Mn P S Al N Cu CrNi Nb Ti Co Mo EXAMPLE A 0.030 0.22 1.74 0.005 0.0005 0.028 0.0037 0.300.26 0.15 0.095 0.014 0.0034 EXAMPLE B MIN 0.020 0.23 1.70 0.004 0.00050.026 0.0030 0.27 0.26 0.16 0.096 0.012 0.0021 EXAMPLE B MAX 0.032 0.261.92 0.009 0.0010 0.035 0.0047 0.32 0.29 0.18 0.120 0.016 0.0050 EXAMPLEC 0.028 0.24 1.77 0.007 0.0008 0.030 0.0035 0.29 0.27 0.17 0.101 0.0140.0028 0.0020 EXAMPLE D 0.08 0.30 0.5 0.07 0.005 0.010 0.10 0.50 0.10EXAMPLE E 0.0028 0.009 0.17 0.011 0.006 0.027 0.0029 0.029 0.014 0.0350.007 EXAMPLE F 0.03 0.1 0.1 0.015 0.005 18.0 0.6 9 5 EXAMPLE G 0.0020.01 0.15 0.07 0.005 0.04 0.0025 0.015 0.010

In an exemplary embodiment, the ratio of the outside diameter D of thetubular members to the wall thickness t of the tubular members rangefrom about 12 to 22 in order to enhance the collapse strength of theradially expanded and plastically deformed tubular members.

In an exemplary embodiment, the outer portion of the wall thickness ofthe radially expanded and plastically deformed tubular members includestensile residual stresses in order to enhance the collapse strengthfollowing radial expansion and plastic deformation.

In several exemplary experimental embodiments, reducing residualstresses in samples of the tubular members prior to radial expansion andplastic deformation increased the collapse strength of the radiallyexpanded and plastically deformed tubular members.

In several exemplary experimental embodiments, the collapse strength ofradially expanded and plastically deformed samples of the tubulars weredetermined on an as-received basis, after strain aging at 250 F for 5hours to reduce residual stresses, and after strain aging at 350 F for14 days to reduce residual stresses as follows: Collapse Strength AfterTubular Sample 10% Radial Expansion Tubular Sample 1 - as received from4000 psi manufacturer Tubular Sample 1 - strain aged at 250 F. for 4800psi 5 hours to reduce residual stresses Tubular Sample 1 - strain agedat 350 F. for 5000 psi 14 days to reduce residual stresses

As indicated by the above table, reducing residual stresses in thetubular members, prior to radial expansion and plastic deformation,significantly increased the resulting collapse strength—post expansion.

In several exemplary experimental embodiments, the collapse strength ofradially expanded and plastically deformed samples of the tubulars weredetermined on an as-received basis, after strain aging at 250 F for 5hours to reduce residual stresses, and after strain aging at 350 F for14 days to reduce residual stresses as follows: Collapse Strength AfterTubular Sample 20% Radial Expansion Tubular Sample 1 - as received from3000 psi manufacturer Tubular Sample 1 - strain aged at 250 F. 4000 psifor 5 hours to reduce residual stresses Tubular Sample 1 - strain agedat 350 F. 4250 psi for 14 days to reduce residual stresses

As indicated by the above table, reducing residual stresses in thetubular members, prior to radial expansion and plastic deformation,significantly increased the resulting collapse strength—post expansion.

In an exemplary experimental embodiment, residual stresses within atubular member were decreased from about −12,000 psi to about −6,000psi, a reduction of about 105%. As a result, the collapse strength ofthe resulting tubular member was increased from about 1550 psi to about1750 psi. This was an unexpected result.

In several exemplary experimental embodiments, tubular members wereradially expanded and plastically deformed using different lubricants toachieve a range of coefficients of friction between the tubular membersand a solid expansion cone during the radial expansion and plasticdeformation of the tubular members. As a result, the followingexperimental results were obtained: RATIO OF DIAMETER WALL TO WALLTHICKNESS COLLAPSE COEFFICIENT EXPANSION THICKNESS AFTER EXPANSIONSTRENGTH SAMPLE OF FRICTION FORCE (lbf) (t) (D/t) (ksi) 1 0.125 145,9000.305 24.8 2,379 2 0.075 143,000 0.350 21.6 3,243 3 0.02 149,900 0.45016.8 5,837 4 0.02 125,800 0.500 15.1 5,359 5 0.02 125,800 0.500 15.18,443

The above tabular experimental results were unexpected. In particular,the resulting collapse strength of the radially expanded and plasticallydeformed tubular was increased by one or more of the following: 1)reducing the coefficient of friction; and/or 2) reducing the ratio ofD/t.

Referring to FIG. 51, in an exemplary experimental embodiment, a sampleof steel pipe, for which the normal manufacturing process was modifiedto include quenching and tempering (the “Quenched and Tempered SteelPipe No. 1”), was tested to generate a stress vs. strain curve 5100. Asillustrated in FIG. 103, the yield point of the curve 5100 was 76.8 ksi.Further stress and strain testing of the Quenched and Tempered SteelPipe No. 1, yielded the following characteristics: Elongation WallThickness Yield Yield/Tensile Longitudinal Width Reduction ReductionStrength Strength % PRIOR % PRIOR TO % PRIOR TO Sample ksi Ratio TOFAILURE FAILURE FAILURE Anisotropy Quenched and 76.8 0.82 16% 32% 45%0.65 Tempered Steel Pipe No. 1

The testing results for the Quenched and Tempered Steel Pipe No. 1,illustrated in FIG. 51, and summarized above in tabular form wereunexpected results. Thus, the modification of the normal manufacturingprocess of the Quenched and Tempered Steel Pipe No. 1, to include aquenching and tempering step, significantly and unexpectedly, enhancedthe performance characteristics of the pipe thereby making the pipeparticularly suited to use as an expandable tubular.

Referring to FIG. 52, in an exemplary experimental embodiment, a sampleof 9⅝″ steel pipe, for which the normal manufacturing process wasmodified to include quenching and tempering (the “Quenched and TemperedSteel Pipe No. 2”), a sample of conventional 9⅝″ NT80-HE steel pipe fromNippon Steel, and a sample of conventional 9⅝″ NT55-HE steel pipe fromNippon Steel were tested to generate stress vs. strain curves 5200,5202, and 5204, for the Quenched and Tempered Steel Pipe No. 2, the 9⅝″NT80-HE steel pipe from Nippon Steel, and the 9⅝″ NT55-HE steel pipefrom Nippon Steel, respectively. As illustrated in FIG. 52, the yieldpoints of the curves 5200, 5202, and 5204, were 84.4 ksi, 61.5 ksi, and73.7 ksi, respectively. Further stress and strain testing of theQuenched and Tempered Steel Pipe No. 2, the 9⅝″ NT80-HE steel pipe fromNippon Steel, and the 9⅝″ NT55-HE steel pipe from Nippon Steel, yieldedthe following characteristics: Elongation Wall Thickness YieldYield/Tensile Longitudinal Width Reduction Reduction Strength Strength %PRIOR TO % PRIOR TO % PRIOR TO Sample ksi Ratio FAILURE FAILURE FAILUREAnisotropy Quenched and 84.4 0.840 20.5% 40.0% 41.8% 0.935 TemperedSteel Pipe No. 2 NT80-HE 61.5 0.62 16.5% 25.5%  47% 0.46 NT55-HE 73.70.67 13.5% 20.4% 37.5% 0.48

The testing results for the Quenched and Tempered Steel Pipe No. 2,illustrated in FIG. 52, and summarized above in tabular form wereunexpected results. Thus, the modification of the normal manufacturingprocess of the Quenched and Tempered Steel Pipe No. 2, to include aquenching and tempering step, significantly and unexpectedly, enhancedthe performance characteristics of the pipe, relative to theconventional NT80-HE and NT55-HE pipes, thereby making the pipeparticularly suited to use as an expandable tubular.

In an exemplary experimental embodiment, samples of steel pipe, forwhich the normal manufacturing process was modified to include quenchingand tempering (the “Quenched and Tempered Steel Pipe Nos. 3 and 4”),were stress and strain tested and exhibited the followingcharacteristics: Value Quenched Quenched and and Tempered Tempered SteelPipe Steel Pipe Characteristic No. 3 No. 4 YIELD STRENGTH 81.25 ksi78.77 ksi Y/T RATIO 0.829 0.822 ELONGATION PRIOR TO FAILURE 14.88%15.90% WIDTH REDUCTION PRIOR TO FAILURE 37.8% 44.0% WALL THICKNESSREDUCTION PRIOR 43.25% 43.33% TO FAILURE ANISOTROPY 0.830 1.03The tabular experimental results presented above were unexpected.

In an exemplary experimental embodiment, samples of steel pipe, forwhich the normal manufacturing process was modified to include quenchingand tempering (the “Quenched and Tempered Steel Pipe No. 5”), werestress and strain tested and exhibited the following characteristics:Characteristic Value YIELD STRENGTH 80.19 ksi Y/T RATIO 0.826 ELONGATIONPRIOR TO FAILURE 15.25% WIDTH REDUCTION PRIOR TO FAILURE 40.4% WALLTHICKNESS REDUCTION PRIOR TO FAILURE 43.3% ANISOTROPY 0.915The tabular experimental results presented above were unexpected.

In an exemplary experimental embodiment, a sample of steel pipe, forwhich the normal manufacturing process was modified to include quenchingand tempering (the “Quenched and Tempered Steel Pipe Nos. 6 and 7”), asample of conventional NT80-HE steel pipe from Nippon Steel, and asample of conventional NT55-HE steel pipe from Nippon Steel were testedto determine absorbed energy and flare expansion characteristics andexhibited the following characteristics: Value Quenched Quenched and andTempered Tempered Steel Pipe Steel Pipe Characteristic No. 6 No. 7NT80-HE NT55-HE ABSORBED 125 ft-lbs 145 ft-lbs 100 ft-lbs  50 ft-lbsENERGY - LONGITUDINAL ABSORBED  59 ft-lbs  59 ft-lbs 40 ft-lbs 30 ft-lbsENERGY - TRANSVERSE ABSORBED 176 ft-lbs 174 ft-lbs 70 ft-lbs  4 ft-lbsENERGY - WELD FLARE EXPANSION 42% 52% 32% 30%

The testing results for the Quenched and Tempered Steel Pipe Nos. 6 and7 summarized above in tabular form were unexpected results. Thus, themodification of the normal manufacturing process of the Quenched andTempered Steel Pipe Nos. 6 and 7, to include a quenching and temperingstep, significantly and unexpectedly, enhanced the performancecharacteristics of the pipe, relative to the conventional NT80-HE andNT55-HE pipes, thereby making the Quenched and Tempered Pipesparticularly suited to use as an expandable tubular.

In an exemplary embodiment, the flare expansion of the Quenched andTempered Steel Pipe Nos. 6 and 7, the sample of conventional NT80-HEsteel pipe from Nippon Steel, and the sample of conventional NT55-HEsteel pipe from Nippon Steel were performed by pressing a tapered solidexpansion cone into an end of the pipe samples to radially expand andplastically deform the ends of the pipe samples.

In an exemplary experimental embodiment, samples of steel pipe, forwhich the normal manufacturing process was modified to include quenchingand tempering (the “Quenched and Tempered Steel Pipe No. 8”), werestress and strain tested and exhibited the following characteristics:Characteristic Value YIELD STRENGTH 88.8 ksi Y/T RATIO 0.86 ELONGATIONPRIOR TO FAILURE 22% WIDTH REDUCTION PRIOR TO FAILURE 39% WALL THICKNESSREDUCTION PRIOR TO FAILURE 41% ANISOTROPY 0.93The tabular experimental results presented above were unexpected.

In an exemplary experimental embodiment, a sample of steel pipe, forwhich the normal manufacturing process was modified to include quenchingand tempering (the “Quenched and Tempered Steel Pipe No. 9”), a sampleof conventional NT80-HE steel pipe from Nippon Steel, and a sample ofconventional NT55-HE steel pipe from Nippon Steel were tested todetermine absorbed energy and flare expansion characteristics andexhibited the following characteristics: Value Quenched and TemperedSteel Characteristic Pipe No. 9 NT80-HE NT55-HE YIELD STRENGTH 84.4 ksi73.7 ksi 61.5 ksi YIELD/TENSILE 0.840 0.67 0.62 STRENGTH RATIOELONGATION 20.5% 13.5% 16.5% BEFORE FAILURE WIDTH REDUCTION 40.0% 20.4%25.5% BEFORE FAILURE WALL THICKNESS 41.8% 37.5% 47% REDUCTION BEFOREFAILURE ANISOTROPY 0.935 0.48 0.46

The testing results for the Quenched and Tempered Steel Pipe No. 9summarized above in tabular form were unexpected results. Thus, themodification of the normal manufacturing process of the Quenched andTempered Steel Pipe No. 9, to include a quenching and tempering step,significantly and unexpectedly, enhanced the performance characteristicsof the pipe, relative to the conventional NT80-HE and NT55-HE pipes,thereby making the Quenched and Tempered Pipes particularly suited touse as an expandable tubular.

In an exemplary experimental embodiment, samples of steel pipe, forwhich the normal manufacturing process was modified to include quenchingand tempering (the “Quenched and Tempered Steel Pipe No. 10”), werestress and strain tested and exhibited the following characteristics:Characteristic Value YIELD STRENGTH 84.6 ksi Y/T RATIO 0.85 ELONGATIONPRIOR TO FAILURE 21% WIDTH REDUCTION PRIOR TO FAILURE 39% WALL THICKNESSREDUCTION PRIOR TO FAILURE 43% ANISOTROPY 0.88The tabular experimental results presented above were unexpected.

In an exemplary embodiment, the composition of the Quench and TemperSteel Pipe Nos. 1 to 10 included the following weight percentages: C SiMn P S Cu Cr Ni 0.27 0.14 1.28 0.009 0.005 0.14

In an exemplary embodiment, the quenching of the Quench and Temper SteelPipe Nos. 1 to 10 was provided at 970 C, and the tempering of the Quenchand Temper Steel Pipe Nos. 1 to 10 was provided for 10 minutes at 670 C.

In an exemplary embodiment, using a combination of empirical,theoretical, and experimental data, electrical resistance pipe (“ERW”)tubular members most suitable for radial expansion and plasticdeformation exhibit the following characteristics: Characteristic ValueABSORBED ENERGY IN THE at least 80 ft-lb LONGITUDINAL DIRECTION ABSORBEDENERGY IN THE at least 60 ft-lb TRANSVERSE DIRECTION ABSORBED ENERGY INTHE at least 60 ft-lb TRANSVERSE WELD AREA FLARE EXPANSION 45% to 75%MINIMUM W/O CRACKS TENSILE STRENGTH 60 TO 120 ksi YIELD STRENGTH 40 TO100 ksi Y/T RATIO 40% to 85% MAXIMUM LONGITUDINAL ELONGATION A MINIMUMOF 22% to 35% PRIOR TO FAILURE WIDTH REDUCTION PRIOR A MINIMUM OF 30% to45% TO FAILURE WALL THICKNESS REDUCTION A MINIMUM OF 30% to 45% PRIOR TOFAILURE ANISOTROPY A MINIMUM OF 0.8 to 1.5

In an exemplary experimental embodiment, based upon theoretical,empirical, and experimental data, tubular members that exhibit thefollowing characteristics are best suited for radial expansion andplastic deformation: Characteristic Value YIELD STRENGTH 50 to 95 ksiY/T RATIO less than 0.5 to 0.82 ELONGATION PRIOR TO FAILURE greater than16 to 30% WIDTH REDUCTION PRIOR TO FAILURE greater than 32 to 45% WALLTHICKNESS REDUCTION PRIOR greater than 30 to 45% TO FAILURE ANISOTROPYgreater than 0.65 to 1.5

In an exemplary embodiment, as illustrated in FIGS. 53 and 54, in anexemplary embodiment, a method 5300 of processing tubular members isimplemented in which, in step 5302, a manufactured tubular member 5302 ais received. In step 5304, the manufactured tubular member 5302 a isthen cold rolled to provide a cold-rolled tubular member 5304 a. In step5306, the cold-rolled tubular member 5304 a is then inter criticalannealed to provide an annealed tubular member 5306 a. In step 5308, theannealed tubular member 5306 a is then positioned within a wellbore andradially expanded and plastically deformed in a conventional manner toprovide a radially expanded and plastically deformed tubular member 5308a. In step 5310, the radially expanded and plastically deformed tubularmember 5308 a is then baked within the wellbore, using the ambienttemperatures within the wellbore, to provide an after-baked tubularmember 5310 a. As illustrated in FIG. 54, the ultimate and final yieldstrength of the after-baked tubular member 5310 a is greater than theyield strength of the manufactured tubular member 5302 a. In anexemplary embodiment, the manufactured tubular member 5302 a is a dualphase steel pipe or a Transformation Induced Plasticity (“TRIP”) steelpipe.

In an exemplary embodiment, the dual phase steel manufactured pipe 5302a includes a microstructure having about 15% to 30% martensite andferrite. In an exemplary embodiment, the dual phase steel manufacturedpipe 5302 a includes a composition of 0.1% C, 1.2% Mn, and 0.3% Si.

In an exemplary embodiment, as illustrated in FIG. 55, when themanufactured pipe 5302 a is a dual phase steel, the initialmicrostructure of the pipe includes ferrite and pearlite. In anexemplary embodiment, in step 5306, the intercritical annealing of thecold rolled pipe 5304 a is performed at about 750 C. As a result of theintercritical annealing, at least some of the pearlite is converted toaustentite. Following the completion of the intercritical annealing instep 15306, the annealed pipe 5306 a is allowed to cool. As a result ofthe cooling, at least some of the austentite in the annealed pipe 5306 ais converted to martensite. In an exemplary embodiment, in step 5310,the baking of the radially expanded and plastically deformed pipe 5308 ais provided within the wellbore at temperatures ranging from about 100 Cto 250 C. In an exemplary embodiment, as a result of the baking step5310, the radially expanded and plastically deformed pipe 5308 a isstress-relieved and bake hardened.

In an exemplary embodiment, in step 15304 of the method 5300, asillustrated in FIG. 56, the temperature of the manufactured steel pipe5302 a follows a curve 5602 in which the steel pipe is deformedthroughout the cooling progression of the curve at a plurality ofseparate stages, 5602 a and 5602 b. In an exemplary embodiment, duringthe first pipe rolling stage 5602 a, insoluble precipitates within thepipe 5302 a retard austentite growth and the deformation also promotesprecipitation. In an exemplary embodiment, during the second piperolling state 5602 b, insoluble precipitates within the pipe 5302 ainhibit recrystallization and austentite grains are conditioned. As aresult, the ultimate yield and collapse strength of the baked pipe 5310a is enhanced.

A method of forming a tubular liner within a preexisting structure hasbeen described that includes positioning a tubular assembly within thepreexisting structure; and radially expanding and plastically deformingthe tubular assembly within the preexisting structure, wherein, prior tothe radial expansion and plastic deformation of the tubular assembly, apredetermined portion of the tubular assembly has a lower yield pointthan another portion of the tubular assembly. In an exemplaryembodiment, the predetermined portion of the tubular assembly has ahigher ductility and a lower yield point prior to the radial expansionand plastic deformation than after the radial expansion and plasticdeformation. In an exemplary embodiment, the predetermined portion ofthe tubular assembly has a higher ductility prior to the radialexpansion and plastic deformation than after the radial expansion andplastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a lower yield point prior to theradial expansion and plastic deformation than after the radial expansionand plastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a larger inside diameter after theradial expansion and plastic deformation than other portions of thetubular assembly. In an exemplary embodiment, the method furtherincludes positioning another tubular assembly within the preexistingstructure in overlapping relation to the tubular assembly; and radiallyexpanding and plastically deforming the other tubular assembly withinthe preexisting structure, wherein, prior to the radial expansion andplastic deformation of the tubular assembly, a predetermined portion ofthe other tubular assembly has a lower yield point than another portionof the other tubular assembly. In an exemplary embodiment, the insidediameter of the radially expanded and plastically deformed other portionof the tubular assembly is equal to the inside diameter of the radiallyexpanded and plastically deformed other portion of the other tubularassembly. In an exemplary embodiment, the predetermined portion of thetubular assembly includes an end portion of the tubular assembly. In anexemplary embodiment, the predetermined portion of the tubular assemblyincludes a plurality of predetermined portions of the tubular assembly.In an exemplary embodiment, the predetermined portion of the tubularassembly includes a plurality of spaced apart predetermined portions ofthe tubular assembly. In an exemplary embodiment, the other portion ofthe tubular assembly includes an end portion of the tubular assembly. Inan exemplary embodiment, the other portion of the tubular assemblyincludes a plurality of other portions of the tubular assembly. In anexemplary embodiment, the other portion of the tubular assembly includesa plurality of spaced apart other portions of the tubular assembly. Inan exemplary embodiment, the tubular assembly includes a plurality oftubular members coupled to one another by corresponding tubularcouplings. In an exemplary embodiment, the tubular couplings include thepredetermined portions of the tubular assembly; and wherein the tubularmembers comprise the other portion of the tubular assembly. In anexemplary embodiment, one or more of the tubular couplings include thepredetermined portions of the tubular assembly. In an exemplaryembodiment, one or more of the tubular members include the predeterminedportions of the tubular assembly. In an exemplary embodiment, thepredetermined portion of the tubular assembly defines one or moreopenings. In an exemplary embodiment, one or more of the openingsinclude slots. In an exemplary embodiment, the anisotropy for thepredetermined portion of the tubular assembly is greater than 1. In anexemplary embodiment, the anisotropy for the predetermined portion ofthe tubular assembly is greater than 1. In an exemplary embodiment, thestrain hardening exponent for the predetermined portion of the tubularassembly is greater than 0.12. In an exemplary embodiment, theanisotropy for the predetermined portion of the tubular assembly isgreater than 1; and the strain hardening exponent for the predeterminedportion of the tubular assembly is greater than 0.12. In an exemplaryembodiment, the predetermined portion of the tubular assembly is a firststeel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si,0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yieldpoint of the predetermined portion of the tubular assembly is at mostabout 46.9 ksi prior to the radial expansion and plastic deformation;and the yield point of the predetermined portion of the tubular assemblyis at least about 65.9 ksi after the radial expansion and plasticdeformation. In an exemplary embodiment, the yield point of thepredetermined portion of the tubular assembly after the radial expansionand plastic deformation is at least about 40% greater than the yieldpoint of the predetermined portion of the tubular assembly prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is about 1.48. Inan exemplary embodiment, the predetermined portion of the tubularassembly includes a second steel alloy including: 0.18% C, 1.28% Mn,0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly is at most about 57.8 ksi prior to the radialexpansion and plastic deformation; and the yield point of thepredetermined portion of the tubular assembly is at least about 74.4 ksiafter the radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly after the radial expansion and plastic deformation is at leastabout 28% greater than the yield point of the predetermined portion ofthe tubular assembly prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.04. In an exemplaryembodiment, the predetermined portion of the tubular assembly includes athird steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S,0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is about 1.92. Inan exemplary embodiment, the predetermined portion of the tubularassembly includes a fourth steel alloy including: 0.02% C, 1.31% Mn,0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplaryembodiment, the anisotropy of the predetermined portion of the tubularassembly, prior to the radial expansion and plastic deformation, isabout 1.34. In an exemplary embodiment, the yield point of thepredetermined portion of the tubular assembly is at most about 46.9 ksiprior to the radial expansion and plastic deformation; and wherein theyield point of the predetermined portion of the tubular assembly is atleast about 65.9 ksi after the radial expansion and plastic deformation.In an exemplary embodiment, the yield point of the predetermined portionof the tubular assembly after the radial expansion and plasticdeformation is at least about 40% greater than the yield point of thepredetermined portion of the tubular assembly prior to the radialexpansion and plastic deformation. In an exemplary embodiment, theanisotropy of the predetermined portion of the tubular assembly, priorto the radial expansion and plastic deformation, is at least about 1.48.In an exemplary embodiment, the yield point of the predetermined portionof the tubular assembly is at most about 57.8 ksi prior to the radialexpansion and plastic deformation; and the yield point of thepredetermined portion of the tubular assembly is at least about 74.4 ksiafter the radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly after the radial expansion and plastic deformation is at leastabout 28% greater than the yield point of the predetermined portion ofthe tubular assembly prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is at least about 1.04. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is at least about 1.92. In an exemplary embodiment, the anisotropy ofthe predetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is at least about 1.34. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,ranges from about 1.04 to about 1.92. In an exemplary embodiment, theyield point of the predetermined portion of the tubular assembly, priorto the radial expansion and plastic deformation, ranges from about 47.6ksi to about 61.7 ksi. In an exemplary embodiment, the expandabilitycoefficient of the predetermined portion of the tubular assembly, priorto the radial expansion and plastic deformation, is greater than 0.12.In an exemplary embodiment, the expandability coefficient of thepredetermined portion of the tubular assembly is greater than theexpandability coefficient of the other portion of the tubular assembly.In an exemplary embodiment, the tubular assembly includes a wellborecasing, a pipeline, or a structural support. In an exemplary embodiment,the carbon content of the predetermined portion of the tubular assemblyis less than or equal to 0.12 percent; and wherein the carbon equivalentvalue for the predetermined portion of the tubular assembly is less than0.21. In an exemplary embodiment, the carbon content of thepredetermined portion of the tubular assembly is greater than 0.12percent; and wherein the carbon equivalent value for the predeterminedportion of the tubular assembly is less than 0.36. In an exemplaryembodiment, a yield point of an inner tubular portion of at least aportion of the tubular assembly is less than a yield point of an outertubular portion of the portion of the tubular assembly. In an exemplaryembodiment, yield point of the inner tubular portion of the tubular bodyvaries as a function of the radial position within the tubular body. Inan exemplary embodiment, the yield point of the inner tubular portion ofthe tubular body varies in an linear fashion as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the inner tubular portion of the tubular body varies in annon-linear fashion as a function of the radial position within thetubular body. In an exemplary embodiment, the yield point of the outertubular portion of the tubular body varies as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the outer tubular portion of the tubular body varies in anlinear fashion as a function of the radial position within the tubularbody. In an exemplary embodiment, the yield point of the outer tubularportion of the tubular body varies in an non-linear fashion as afunction of the radial position within the tubular body. In an exemplaryembodiment, the yield point of the inner tubular portion of the tubularbody varies as a function of the radial position within the tubularbody; and wherein the yield point of the outer tubular portion of thetubular body varies as a function of the radial position within thetubular body. In an exemplary embodiment, the yield point of the innertubular portion of the tubular body varies in a linear fashion as afunction of the radial position within the tubular body; and wherein theyield point of the outer tubular portion of the tubular body varies in alinear fashion as a function of the radial position within the tubularbody. In an exemplary embodiment, the yield point of the inner tubularportion of the tubular body varies in a linear fashion as a function ofthe radial position within the tubular body; and wherein the yield pointof the outer tubular portion of the tubular body varies in a non-linearfashion as a function of the radial position within the tubular body. Inan exemplary embodiment, the yield point of the inner tubular portion ofthe tubular body varies in a non-linear fashion as a function of theradial position within the tubular body; and wherein the yield point ofthe outer tubular portion of the tubular body varies in a linear fashionas a function of the radial position within the tubular body. In anexemplary embodiment, the yield point of the inner tubular portion ofthe tubular body varies in a non-linear fashion as a function of theradial position within the tubular body; and wherein the yield point ofthe outer tubular portion of the tubular body varies in a non-linearfashion as a function of the radial position within the tubular body. Inan exemplary embodiment, the rate of change of the yield point of theinner tubular portion of the tubular body is different than the rate ofchange of the yield point of the outer tubular portion of the tubularbody. In an exemplary embodiment, the rate of change of the yield pointof the inner tubular portion of the tubular body is different than therate of change of the yield point of the outer tubular portion of thetubular body. In an exemplary embodiment, prior to the radial expansionand plastic deformation, at least a portion of the tubular assemblycomprises a microstructure comprising a hard phase structure and a softphase structure. In an exemplary embodiment, prior to the radialexpansion and plastic deformation, at least a portion of the tubularassembly comprises a microstructure comprising a transitional phasestructure. In an exemplary embodiment, the hard phase structurecomprises martensite. In an exemplary embodiment, the soft phasestructure comprises ferrite. In an exemplary embodiment, thetransitional phase structure comprises retained austentite. In anexemplary embodiment, the hard phase structure comprises martensite;wherein the soft phase structure comprises ferrite; and wherein thetransitional phase structure comprises retained austentite. In anexemplary embodiment, the portion of the tubular assembly comprising amicrostructure comprising a hard phase structure and a soft phasestructure comprises, by weight percentage, about 0.1% C, about 1.2% Mn,and about 0.3% Si.

An expandable tubular member has been described that includes a steelalloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01%Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, a yield point ofthe tubular member is at most about 46.9 ksi prior to a radial expansionand plastic deformation; and a yield point of the tubular member is atleast about 65.9 ksi after the radial expansion and plastic deformation.In an exemplary embodiment, the yield point of the tubular member afterthe radial expansion and plastic deformation is at least about 40%greater than the yield point of the tubular member prior to the radialexpansion and plastic deformation. In an exemplary embodiment, theanisotropy of the tubular member, prior to a radial expansion andplastic deformation, is about 1.48. In an exemplary embodiment, thetubular member includes a wellbore casing, a pipeline, or a structuralsupport.

An expandable tubular member has been described that includes a steelalloy including: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01%Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, a yield point ofthe tubular member is at most about 57.8 ksi prior to a radial expansionand plastic deformation; and the yield point of the tubular member is atleast about 74.4 ksi after the radial expansion and plastic deformation.In an exemplary embodiment, a yield point of the of the tubular memberafter a radial expansion and plastic deformation is at least about 28%greater than the yield point of the tubular member prior to the radialexpansion and plastic deformation. In an exemplary embodiment, theanisotropy of the tubular member, prior to a radial expansion andplastic deformation, is about 1.04. In an exemplary embodiment, thetubular member includes a wellbore casing, a pipeline, or a structuralsupport.

An expandable tubular member has been described that includes a steelalloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16%Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropyof the tubular member, prior to a radial expansion and plasticdeformation, is about 1.92. In an exemplary embodiment, the tubularmember includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described that includes a steelalloy including: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1%Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of thetubular member, prior to a radial expansion and plastic deformation, isabout 1.34. In an exemplary embodiment, the tubular member includes awellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the yield pointof the expandable tubular member is at most about 46.9 ksi prior to aradial expansion and plastic deformation; and wherein the yield point ofthe expandable tubular member is at least about 65.9 ksi after theradial expansion and plastic deformation. In an exemplary embodiment,the tubular member includes a wellbore casing, a pipeline, or astructural support.

An expandable tubular member has been described, wherein a yield pointof the expandable tubular member after a radial expansion and plasticdeformation is at least about 40% greater than the yield point of theexpandable tubular member prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the tubular member includes awellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the anisotropyof the expandable tubular member, prior to the radial expansion andplastic deformation, is at least about 1.48. In an exemplary embodiment,the tubular member includes a wellbore casing, a pipeline, or astructural support.

An expandable tubular member has been described, wherein the yield pointof the expandable tubular member is at most about 57.8 ksi prior to theradial expansion and plastic deformation; and wherein the yield point ofthe expandable tubular member is at least about 74.4 ksi after theradial expansion and plastic deformation. In an exemplary embodiment,the tubular member includes a wellbore casing, a pipeline, or astructural support.

An expandable tubular member has been described, wherein the yield pointof the expandable tubular member after a radial expansion and plasticdeformation is at least about 28% greater than the yield point of theexpandable tubular member prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the tubular member includes awellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the anisotropyof the expandable tubular member, prior to the radial expansion andplastic deformation, is at least about 1.04. In an exemplary embodiment,the tubular member includes a wellbore casing, a pipeline, or astructural support.

An expandable tubular member has been described, wherein the anisotropyof the expandable tubular member, prior to the radial expansion andplastic deformation, is at least about 1.92. In an exemplary embodiment,the tubular member includes a wellbore casing, a pipeline, or astructural support.

An expandable tubular member has been described, wherein the anisotropyof the expandable tubular member, prior to the radial expansion andplastic deformation, is at least about 1.34. In an exemplary embodiment,the tubular member includes a wellbore casing, a pipeline, or astructural support.

An expandable tubular member has been described, wherein the anisotropyof the expandable tubular member, prior to the radial expansion andplastic deformation, ranges from about 1.04 to about 1.92. In anexemplary embodiment, the tubular member includes a wellbore casing, apipeline, or a structural support.

An expandable tubular member has been described, wherein the yield pointof the expandable tubular member, prior to the radial expansion andplastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In anexemplary embodiment, the tubular member includes a wellbore casing, apipeline, or a structural support.

An expandable tubular member has been described, wherein theexpandability coefficient of the expandable tubular member, prior to theradial expansion and plastic deformation, is greater than 0.12. In anexemplary embodiment, the tubular member includes a wellbore casing, apipeline, or a structural support.

An expandable tubular member has been described, wherein theexpandability coefficient of the expandable tubular member is greaterthan the expandability coefficient of another portion of the expandabletubular member. In an exemplary embodiment, the tubular member includesa wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the tubularmember has a higher ductility and a lower yield point prior to a radialexpansion and plastic deformation than after the radial expansion andplastic deformation. In an exemplary embodiment, the tubular memberincludes a wellbore casing, a pipeline, or a structural support.

A method of radially expanding and plastically deforming a tubularassembly including a first tubular member coupled to a second tubularmember has been described that includes radially expanding andplastically deforming the tubular assembly within a preexistingstructure; and using less power to radially expand each unit length ofthe first tubular member than to radially expand each unit length of thesecond tubular member. In an exemplary embodiment, the tubular memberincludes a wellbore casing, a pipeline, or a structural support.

A system for radially expanding and plastically deforming a tubularassembly including a first tubular member coupled to a second tubularmember has been described that includes means for radially expanding thetubular assembly within a preexisting structure; and means for usingless power to radially expand each unit length of the first tubularmember than required to radially expand each unit length of the secondtubular member. In an exemplary embodiment, the tubular member includesa wellbore casing, a pipeline, or a structural support.

A method of manufacturing a tubular member has been described thatincludes processing a tubular member until the tubular member ischaracterized by one or more intermediate characteristics; positioningthe tubular member within a preexisting structure; and processing thetubular member within the preexisting structure until the tubular memberis characterized one or more final characteristics. In an exemplaryembodiment, the tubular member includes a wellbore casing, a pipeline,or a structural support. In an exemplary embodiment, the preexistingstructure includes a wellbore that traverses a subterranean formation.In an exemplary embodiment, the characteristics are selected from agroup consisting of yield point and ductility. In an exemplaryembodiment, processing the tubular member within the preexistingstructure until the tubular member is characterized one or more finalcharacteristics includes: radially expanding and plastically deformingthe tubular member within the preexisting structure.

An apparatus has been described that includes an expandable tubularassembly; and an expansion device coupled to the expandable tubularassembly; wherein a predetermined portion of the expandable tubularassembly has a lower yield point than another portion of the expandabletubular assembly. In an exemplary embodiment, the expansion deviceincludes a rotary expansion device, an axially displaceable expansiondevice, a reciprocating expansion device, a hydroforming expansiondevice, and/or an impulsive force expansion device. In an exemplaryembodiment, the predetermined portion of the tubular assembly has ahigher ductility and a lower yield point than another portion of theexpandable tubular assembly. In an exemplary embodiment, thepredetermined portion of the tubular assembly has a higher ductilitythan another portion of the expandable tubular assembly. In an exemplaryembodiment, the predetermined portion of the tubular assembly has alower yield point than another portion of the expandable tubularassembly. In an exemplary embodiment, the predetermined portion of thetubular assembly includes an end portion of the tubular assembly. In anexemplary embodiment, the predetermined portion of the tubular assemblyincludes a plurality of predetermined portions of the tubular assembly.In an exemplary embodiment, the predetermined portion of the tubularassembly includes a plurality of spaced apart predetermined portions ofthe tubular assembly. In an exemplary embodiment, the other portion ofthe tubular assembly includes an end portion of the tubular assembly. Inan exemplary embodiment, the other portion of the tubular assemblyincludes a plurality of other portions of the tubular assembly. In anexemplary embodiment, the other portion of the tubular assembly includesa plurality of spaced apart other portions of the tubular assembly. Inan exemplary embodiment, the tubular assembly includes a plurality oftubular members coupled to one another by corresponding tubularcouplings. In an exemplary embodiment, the tubular couplings comprisethe predetermined portions of the tubular assembly; and wherein thetubular members comprise the other portion of the tubular assembly. Inan exemplary embodiment, one or more of the tubular couplings comprisethe predetermined portions of the tubular assembly. In an exemplaryembodiment, one or more of the tubular members comprise thepredetermined portions of the tubular assembly. In an exemplaryembodiment, the predetermined portion of the tubular assembly definesone or more openings. In an exemplary embodiment, one or more of theopenings comprise slots. In an exemplary embodiment, the anisotropy forthe predetermined portion of the tubular assembly is greater than 1 Inan exemplary embodiment, the anisotropy for the predetermined portion ofthe tubular assembly is greater than 1. In an exemplary embodiment, thestrain hardening exponent for the predetermined portion of the tubularassembly is greater than 0.12. In an exemplary embodiment, theanisotropy for the predetermined portion of the tubular assembly isgreater than 1; and wherein the strain hardening exponent for thepredetermined portion of the tubular assembly is greater than 0.12. Inan exemplary embodiment, the predetermined portion of the tubularassembly includes a first steel alloy including: 0.065% C, 1.44% Mn,0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly is at most about 46.9 ksi. In an exemplaryembodiment, the anisotropy of the predetermined portion of the tubularassembly is about 1.48. In an exemplary embodiment, the predeterminedportion of the tubular assembly includes a second steel alloy including:0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and0.03% Cr. In an exemplary embodiment, the yield point of thepredetermined portion of the tubular assembly is at most about 57.8 ksi.In an exemplary embodiment, the anisotropy of the predetermined portionof the tubular assembly is about 1.04. In an exemplary embodiment, thepredetermined portion of the tubular assembly includes a third steelalloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16%Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropyof the predetermined portion of the tubular assembly is about 1.92. Inan exemplary embodiment, the predetermined portion of the tubularassembly includes a fourth steel alloy including: 0.02% C, 1.31% Mn,0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplaryembodiment, the anisotropy of the predetermined portion of the tubularassembly is at least about 1.34. In an exemplary embodiment, the yieldpoint of the predetermined portion of the tubular assembly is at mostabout 46.9 ksi. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly is at least about 1.48. Inan exemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly is at most about 57.8 ksi. In an exemplaryembodiment, the anisotropy of the predetermined portion of the tubularassembly is at least about 1.04. In an exemplary embodiment, theanisotropy of the predetermined portion of the tubular assembly is atleast about 1.92. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly is at least about 1.34. Inan exemplary embodiment, the anisotropy of the predetermined portion ofthe tubular assembly ranges from about 1.04 to about 1.92. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly ranges from about 47.6 ksi to about 61.7 ksi. In anexemplary embodiment, the expandability coefficient of the predeterminedportion of the tubular assembly is greater than 0.12. In an exemplaryembodiment, the expandability coefficient of the predetermined portionof the tubular assembly is greater than the expandability coefficient ofthe other portion of the tubular assembly. In an exemplary embodiment,the tubular assembly includes a wellbore casing, a pipeline, or astructural support. In an exemplary embodiment, the carbon content ofthe predetermined portion of the tubular assembly is less than or equalto 0.12 percent; and wherein the carbon equivalent value for thepredetermined portion of the tubular assembly is less than 0.21. In anexemplary embodiment, the carbon content of the predetermined portion ofthe tubular assembly is greater than 0.12 percent; and wherein thecarbon equivalent value for the predetermined portion of the tubularassembly is less than 0.36. In an exemplary embodiment, a yield point ofan inner tubular portion of at least a portion of the tubular assemblyis less than a yield point of an outer tubular portion of the portion ofthe tubular assembly. In an exemplary embodiment, the yield point of theinner tubular portion of the tubular body varies as a function of theradial position within the tubular body. In an exemplary embodiment, theyield point of the inner tubular portion of the tubular body varies inan linear fashion as a function of the radial position within thetubular body. In an exemplary embodiment, the yield point of the innertubular portion of the tubular body varies in an non-linear fashion as afunction of the radial position within the tubular body. In an exemplaryembodiment, the yield point of the outer tubular portion of the tubularbody varies as a function of the radial position within the tubularbody. In an exemplary embodiment, the yield point of the outer tubularportion of the tubular body varies in an linear fashion as a function ofthe radial position within the tubular body. In an exemplary embodiment,the yield point of the outer tubular portion of the tubular body variesin an non-linear fashion as a function of the radial position within thetubular body. In an exemplary embodiment, the yield point of the innertubular portion of the tubular body varies as a function of the radialposition within the tubular body; and wherein the yield point of theouter tubular portion of the tubular body varies as a function of theradial position within the tubular body. In an exemplary embodiment, theyield point of the inner tubular portion of the tubular body varies in alinear fashion as a function of the radial position within the tubularbody; and wherein the yield point of the outer tubular portion of thetubular body varies in a linear fashion as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the inner tubular portion of the tubular body varies in alinear fashion as a function of the radial position within the tubularbody; and wherein the yield point of the outer tubular portion of thetubular body varies in a non-linear fashion as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the inner tubular portion of the tubular body varies in anon-linear fashion as a function of the radial position within thetubular body; and wherein the yield point of the outer tubular portionof the tubular body varies in a linear fashion as a function of theradial position within the tubular body. In an exemplary embodiment, theyield point of the inner tubular portion of the tubular body varies in anon-linear fashion as a function of the radial position within thetubular body; and wherein the yield point of the outer tubular portionof the tubular body varies in a non-linear fashion as a function of theradial position within the tubular body. In an exemplary embodiment, therate of change of the yield point of the inner tubular portion of thetubular body is different than the rate of change of the yield point ofthe outer tubular portion of the tubular body. In an exemplaryembodiment, the rate of change of the yield point of the inner tubularportion of the tubular body is different than the rate of change of theyield point of the outer tubular portion of the tubular body. In anexemplary embodiment, at least a portion of the tubular assemblycomprises a microstructure comprising a hard phase structure and a softphase structure. In an exemplary embodiment, prior to the radialexpansion and plastic deformation, at least a portion of the tubularassembly comprises a microstructure comprising a transitional phasestructure. In an exemplary embodiment, wherein the hard phase structurecomprises martensite. In an exemplary embodiment, wherein the soft phasestructure comprises ferrite. In an exemplary embodiment, wherein thetransitional phase structure comprises retained austentite. In anexemplary embodiment, the hard phase structure comprises martensite;wherein the soft phase structure comprises ferrite; and wherein thetransitional phase structure comprises retained austentite. In anexemplary embodiment, the portion of the tubular assembly comprising amicrostructure comprising a hard phase structure and a soft phasestructure comprises, by weight percentage, about 0.1% C, about 1.2% Mn,and about 0.3% Si. In an exemplary embodiment, at least a portion of thetubular assembly comprises a microstructure comprising a hard phasestructure and a soft phase structure. In an exemplary embodiment, theportion of the tubular assembly comprises, by weight percentage, 0.065%C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr,0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti. In an exemplary embodiment,the portion of the tubular assembly comprises, by weight percentage,0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni,0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti. In an exemplaryembodiment, the portion of the tubular assembly comprises, by weightpercentage, 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu,0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti. In anexemplary embodiment, the portion of the tubular assembly comprises amicrostructure comprising one or more of the following: martensite,pearlite, vanadium carbide, nickel carbide, or titanium carbide. In anexemplary embodiment, the portion of the tubular assembly comprises amicrostructure comprising one or more of the following: pearlite orpearlite striation. In an exemplary embodiment, the portion of thetubular assembly comprises a microstructure comprising one or more ofthe following: grain pearlite, widmanstatten martensite, vanadiumcarbide, nickel carbide, or titanium carbide. In an exemplaryembodiment, the portion of the tubular assembly comprises amicrostructure comprising one or more of the following: ferrite, grainpearlite, or martensite. In an exemplary embodiment, the portion of thetubular assembly comprises a microstructure comprising one or more ofthe following: ferrite, martensite, or bainite. In an exemplaryembodiment, the portion of the tubular assembly comprises amicrostructure comprising one or more of the following: bainite,pearlite, or ferrite. In an exemplary embodiment, the portion of thetubular assembly comprises a yield strength of about 67 ksi and atensile strength of about 95 ksi. In an exemplary embodiment, theportion of the tubular assembly comprises a yield strength of about 82ksi and a tensile strength of about 130 ksi. In an exemplary embodiment,the portion of the tubular assembly comprises a yield strength of about60 ksi and a tensile strength of about 97 ksi.

An expandable tubular member has been described, wherein a yield pointof the expandable tubular member after a radial expansion and plasticdeformation is at least about 5.8% greater than the yield point of theexpandable tubular member prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the tubular member includes awellbore casing, a pipeline, or a structural support.

A method of determining the expandability of a selected tubular memberhas been described that includes determining an anisotropy value for theselected tubular member, determining a strain hardening value for theselected tubular member; and multiplying the anisotropy value times thestrain hardening value to generate an expandability value for theselected tubular member. In an exemplary embodiment, an anisotropy valuegreater than 0.12 indicates that the tubular member is suitable forradial expansion and plastic deformation. In an exemplary embodiment,the tubular member includes a wellbore casing, a pipeline, or astructural support.

A method of radially expanding and plastically deforming tubular membershas been described that includes selecting a tubular member; determiningan anisotropy value for the selected tubular member; determining astrain hardening value for the selected tubular member; multiplying theanisotropy value times the strain hardening value to generate anexpandability value for the selected tubular member; and if theanisotropy value is greater than 0.12, then radially expanding andplastically deforming the selected tubular member. In an exemplaryembodiment, the tubular member includes a wellbore casing, a pipeline,or a structural support. In an exemplary embodiment, radially expandingand plastically deforming the selected tubular member includes:inserting the selected tubular member into a preexisting structure; andthen radially expanding and plastically deforming the selected tubularmember. In an exemplary embodiment, the preexisting structure includes awellbore that traverses a subterranean formation.

A radially expandable multiple tubular member apparatus has beendescribed that includes a first tubular member; a second tubular memberengaged with the first tubular member forming a joint; a sleeveoverlapping and coupling the first and second tubular members at thejoint; the sleeve having opposite tapered ends and a flange engaged in arecess formed in an adjacent tubular member; and one of the tapered endsbeing a surface formed on the flange. In an exemplary embodiment, therecess includes a tapered wall in mating engagement with the tapered endformed on the flange. In an exemplary embodiment, the sleeve includes aflange at each tapered end and each tapered end is formed on arespective flange. In an exemplary embodiment, each tubular memberincludes a recess. In an exemplary embodiment, each flange is engaged ina respective one of the recesses. In an exemplary embodiment, eachrecess includes a tapered wall in mating engagement with the tapered endformed on a respective one of the flanges.

A method of joining radially expandable multiple tubular members hasalso been described that includes providing a first tubular member;engaging a second tubular member with the first tubular member to form ajoint; providing a sleeve having opposite tapered ends and a flange, oneof the tapered ends being a surface formed on the flange; and mountingthe sleeve for overlapping and coupling the first and second tubularmembers at the joint, wherein the flange is engaged in a recess formedin an adjacent one of the tubular members. In an exemplary embodiment,the method further includes providing a tapered wall in the recess formating engagement with the tapered end formed on the flange. In anexemplary embodiment, the method further includes providing a flange ateach tapered end wherein each tapered end is formed on a respectiveflange. In an exemplary embodiment, the method further includesproviding a recess in each tubular member. In an exemplary embodiment,the method further includes engaging each flange in a respective one ofthe recesses. In an exemplary embodiment, the method further includesproviding a tapered wall in each recess for mating engagement with thetapered end formed on a respective one of the flanges.

A radially expandable multiple tubular member apparatus has beendescribed that includes a first tubular member; a second tubular memberengaged with the first tubular member forming a joint; and a sleeveoverlapping and coupling the first and second tubular members at thejoint; wherein at least a portion of the sleeve is comprised of afrangible material.

A radially expandable multiple tubular member apparatus has beendescribed that includes a first tubular member; a second tubular memberengaged with the first tubular member forming a joint; and a sleeveoverlapping and coupling the first and second tubular members at thejoint; wherein the wall thickness of the sleeve is variable.

A method of joining radially expandable multiple tubular members hasbeen described that includes providing a first tubular member; engaginga second tubular member with the first tubular member to form a joint;providing a sleeve comprising a frangible material; and mounting thesleeve for overlapping and coupling the first and second tubular membersat the joint.

A method of joining radially expandable multiple tubular members hasbeen described that includes providing a first tubular member; engaginga second tubular member with the first tubular member to form a joint;providing a sleeve comprising a variable wall thickness; and mountingthe sleeve for overlapping and coupling the first and second tubularmembers at the joint.

An expandable tubular assembly has been described that includes a firsttubular member; a second tubular member coupled to the first tubularmember; and means for increasing the axial compression loading capacityof the coupling between the first and second tubular members before andafter a radial expansion and plastic deformation of the first and secondtubular members.

An expandable tubular assembly has been described that includes a firsttubular member; a second tubular member coupled to the first tubularmember; and means for increasing the axial tension loading capacity ofthe coupling between the first and second tubular members before andafter a radial expansion and plastic deformation of the first and secondtubular members.

An expandable tubular assembly has been described that includes a firsttubular member; a second tubular member coupled to the first tubularmember; and means for increasing the axial compression and tensionloading capacity of the coupling between the first and second tubularmembers before and after a radial expansion and plastic deformation ofthe first and second tubular members.

An expandable tubular assembly has been described that includes a firsttubular member; a second tubular member coupled to the first tubularmember; and means for avoiding stress risers in the coupling between thefirst and second tubular members before and after a radial expansion andplastic deformation of the first and second tubular members.

An expandable tubular assembly has been described that includes a firsttubular member; a second tubular member coupled to the first tubularmember; and means for inducing stresses at selected portions of thecoupling between the first and second tubular members before and after aradial expansion and plastic deformation of the first and second tubularmembers.

In several exemplary embodiments of the apparatus described above, thesleeve is circumferentially tensioned; and wherein the first and secondtubular members are circumferentially compressed.

In several exemplary embodiments of the method described above, themethod further includes maintaining the sleeve in circumferentialtension; and maintaining the first and second tubular members incircumferential compression before, during, and/or after the radialexpansion and plastic deformation of the first and second tubularmembers.

An expandable tubular assembly has been described that includes a firsttubular member, a second tubular member coupled to the first tubularmember, a first threaded connection for coupling a portion of the firstand second tubular members, a second threaded connection spaced apartfrom the first threaded connection for coupling another portion of thefirst and second tubular members, a tubular sleeve coupled to andreceiving end portions of the first and second tubular members, and asealing element positioned between the first and second spaced apartthreaded connections for sealing an interface between the first andsecond tubular member, wherein the sealing element is positioned withinan annulus defined between the first and second tubular members. In anexemplary embodiment, the annulus is at least partially defined by anirregular surface. In an exemplary embodiment, the annulus is at leastpartially defined by a toothed surface. In an exemplary embodiment, thesealing element comprises an elastomeric material. In an exemplaryembodiment, the sealing element comprises a metallic material. In anexemplary embodiment, the sealing element comprises an elastomeric and ametallic material.

A method of joining radially expandable multiple tubular members hasbeen described that includes providing a first tubular member, providinga second tubular member, providing a sleeve, mounting the sleeve foroverlapping and coupling the first and second tubular members,threadably coupling the first and second tubular members at a firstlocation, threadably coupling the first and second tubular members at asecond location spaced apart from the first location, and sealing aninterface between the first and second tubular members between the firstand second locations using a compressible sealing element. In anexemplary embodiment, the sealing element includes an irregular surface.In an exemplary embodiment, the sealing element includes a toothedsurface. In an exemplary embodiment, the sealing element comprises anelastomeric material. In an exemplary embodiment, the sealing elementcomprises a metallic material. In an exemplary embodiment, the sealingelement comprises an elastomeric and a metallic material.

An expandable tubular assembly has been described that includes a firsttubular member, a second tubular member coupled to the first tubularmember, a first threaded connection for coupling a portion of the firstand second tubular members, a second threaded connection spaced apartfrom the first threaded connection for coupling another portion of thefirst and second tubular members, and a plurality of spaced aparttubular sleeves coupled to and receiving end portions of the first andsecond tubular members. In an exemplary embodiment, at least one of thetubular sleeves is positioned in opposing relation to the first threadedconnection; and wherein at least one of the tubular sleeves ispositioned in opposing relation to the second threaded connection. In anexemplary embodiment, at least one of the tubular sleeves is notpositioned in opposing relation to the first and second threadedconnections.

A method of joining radially expandable multiple tubular members hasbeen described that includes providing a first tubular member, providinga second tubular member, threadably coupling the first and secondtubular members at a first location, threadably coupling the first andsecond tubular members at a second location spaced apart from the firstlocation, providing a plurality of sleeves, and mounting the sleeves atspaced apart locations for overlapping and coupling the first and secondtubular members. In an exemplary embodiment, at least one of the tubularsleeves is positioned in opposing relation to the first threadedcoupling; and wherein at least one of the tubular sleeves is positionedin opposing relation to the second threaded coupling. In an exemplaryembodiment, at least one of the tubular sleeves is not positioned inopposing relation to the first and second threaded couplings.

An expandable tubular assembly has been described that includes a firsttubular member, a second tubular member coupled to the first tubularmember, and a plurality of spaced apart tubular sleeves coupled to andreceiving end portions of the first and second tubular members.

A method of joining radially expandable multiple tubular members hasbeen described that includes providing a first tubular member, providinga second tubular member, providing a plurality of sleeves, coupling thefirst and second tubular members, and mounting the sleeves at spacedapart locations for overlapping and coupling the first and secondtubular members.

An expandable tubular assembly has been described that includes a firsttubular member, a second tubular member coupled to the first tubularmember, a threaded connection for coupling a portion of the first andsecond tubular members, and a tubular sleeves coupled to and receivingend portions of the first and second tubular members, wherein at least aportion of the threaded connection is upset. In an exemplary embodiment,at least a portion of tubular sleeve penetrates the first tubularmember.

A method of joining radially expandable multiple tubular members hasbeen described that includes providing a first tubular member, providinga second tubular member, threadably coupling the first and secondtubular members, and upsetting the threaded coupling. In an exemplaryembodiment, the first tubular member further comprises an annularextension extending therefrom, and the flange of the sleeve defines anannular recess for receiving and mating with the annular extension ofthe first tubular member. In an exemplary embodiment, the first tubularmember further comprises an annular extension extending therefrom; andthe flange of the sleeve defines an annular recess for receiving andmating with the annular extension of the first tubular member.

A radially expandable multiple tubular member apparatus has beendescribed that includes a first tubular member, a second tubular memberengaged with the first tubular member forming a joint, a sleeveoverlapping and coupling the first and second tubular members at thejoint, and one or more stress concentrators for concentrating stressesin the joint. In an exemplary embodiment, one or more of the stressconcentrators comprises one or more external grooves defined in thefirst tubular member. In an exemplary embodiment, one or more of thestress concentrators comprises one or more internal grooves defined inthe second tubular member. In an exemplary embodiment, one or more ofthe stress concentrators comprises one or more openings defined in thesleeve. In an exemplary embodiment, one or more of the stressconcentrators comprises one or more external grooves defined in thefirst tubular member; and one or more of the stress concentratorscomprises one or more internal grooves defined in the second tubularmember. In an exemplary embodiment, one or more of the stressconcentrators comprises one or more external grooves defined in thefirst tubular member; and one or more of the stress concentratorscomprises one or more openings defined in the sleeve. In an exemplaryembodiment, one or more of the stress concentrators comprises one ormore internal grooves defined in the second tubular member; and one ormore of the stress concentrators comprises one or more openings definedin the sleeve. In an exemplary embodiment, one or more of the stressconcentrators comprises one or more external grooves defined in thefirst tubular member; wherein one or more of the stress concentratorscomprises one or more internal grooves defined in the second tubularmember; and wherein one or more of the stress concentrators comprisesone or more openings defined in the sleeve.

A method of joining radially expandable multiple tubular members hasbeen described that includes providing a first tubular member, engaginga second tubular member with the first tubular member to form a joint,providing a sleeve having opposite tapered ends and a flange, one of thetapered ends being a surface formed on the flange, and concentratingstresses within the joint. In an exemplary embodiment, concentratingstresses within the joint comprises using the first tubular member toconcentrate stresses within the joint. In an exemplary embodiment,concentrating stresses within the joint comprises using the secondtubular member to concentrate stresses within the joint. In an exemplaryembodiment, concentrating stresses within the joint comprises using thesleeve to concentrate stresses within the joint. In an exemplaryembodiment, concentrating stresses within the joint comprises using thefirst tubular member and the second tubular member to concentratestresses within the joint. In an exemplary embodiment, concentratingstresses within the joint comprises using the first tubular member andthe sleeve to concentrate stresses within the joint. In an exemplaryembodiment, concentrating stresses within the joint comprises using thesecond tubular member and the sleeve to concentrate stresses within thejoint. In an exemplary embodiment, concentrating stresses within thejoint comprises using the first tubular member, the second tubularmember, and the sleeve to concentrate stresses within the joint.

A system for radially expanding and plastically deforming a firsttubular member coupled to a second tubular member by a mechanicalconnection has been described that includes means for radially expandingthe first and second tubular members, and means for maintaining portionsof the first and second tubular member in circumferential compressionfollowing the radial expansion and plastic deformation of the first andsecond tubular members.

A system for radially expanding and plastically deforming a firsttubular member coupled to a second tubular member by a mechanicalconnection has been described that includes means for radially expandingthe first and second tubular members; and means for concentratingstresses within the mechanical connection during the radial expansionand plastic deformation of the first and second tubular members.

A system for radially expanding and plastically deforming a firsttubular member coupled to a second tubular member by a mechanicalconnection has been described that includes means for radially expandingthe first and second tubular members; means for maintaining portions ofthe first and second tubular member in circumferential compressionfollowing the radial expansion and plastic deformation of the first andsecond tubular members; and means for concentrating stresses within themechanical connection during the radial expansion and plasticdeformation of the first and second tubular members.

A radially expandable tubular member apparatus has been described thatincludes a first tubular member; a second tubular member engaged withthe first tubular member forming a joint; and a sleeve overlapping andcoupling the first and second tubular members at the joint; wherein,prior to a radial expansion and plastic deformation of the apparatus, apredetermined portion of the apparatus has a lower yield point thananother portion of the apparatus. In an exemplary embodiment, the carboncontent of the predetermined portion of the apparatus is less than orequal to 0.12 percent; and wherein the carbon equivalent value for thepredetermined portion of the apparatus is less than 0.21. In anexemplary embodiment, the carbon content of the predetermined portion ofthe apparatus is greater than 0.12 percent; and wherein the carbonequivalent value for the predetermined portion of the apparatus is lessthan 0.36. In an exemplary embodiment, the apparatus further includesmeans for maintaining portions of the first and second tubular member incircumferential compression following the radial expansion and plasticdeformation of the first and second tubular members. In an exemplaryembodiment, the apparatus further includes means for concentratingstresses within the mechanical connection during the radial expansionand plastic deformation of the first and second tubular members. In anexemplary embodiment, the apparatus further includes means formaintaining portions of the first and second tubular member incircumferential compression following the radial expansion and plasticdeformation of the first and second tubular members; and means forconcentrating stresses within the mechanical connection during theradial expansion and plastic deformation of the first and second tubularmembers. In an exemplary embodiment, the apparatus further includes oneor more stress concentrators for concentrating stresses in the joint. Inan exemplary embodiment, one or more of the stress concentratorscomprises one or more external grooves defined in the first tubularmember. In an exemplary embodiment, one or more of the stressconcentrators comprises one or more internal grooves defined in thesecond tubular member. In an exemplary embodiment, one or more of thestress concentrators comprises one or more openings defined in thesleeve. In an exemplary embodiment, one or more of the stressconcentrators comprises one or more external grooves defined in thefirst tubular member; and wherein one or more of the stressconcentrators comprises one or more internal grooves defined in thesecond tubular member. In an exemplary embodiment, one or more of thestress concentrators comprises one or more external grooves defined inthe first tubular member; and wherein one or more of the stressconcentrators comprises one or more openings defined in the sleeve. Inan exemplary embodiment, one or more of the stress concentratorscomprises one or more internal grooves defined in the second tubularmember; and wherein one or more of the stress concentrators comprisesone or more openings defined in the sleeve. In an exemplary embodiment,one or more of the stress concentrators comprises one or more externalgrooves defined in the first tubular member; wherein one or more of thestress concentrators comprises one or more internal grooves defined inthe second tubular member; and wherein one or more of the stressconcentrators comprises one or more openings defined in the sleeve. Inan exemplary embodiment, the first tubular member further comprises anannular extension extending therefrom; and wherein the flange of thesleeve defines an annular recess for receiving and mating with theannular extension of the first tubular member. In an exemplaryembodiment, the apparatus further includes a threaded connection forcoupling a portion of the first and second tubular members; wherein atleast a portion of the threaded connection is upset. In an exemplaryembodiment, at least a portion of tubular sleeve penetrates the firsttubular member. In an exemplary embodiment, the apparatus furtherincludes means for increasing the axial compression loading capacity ofthe joint between the first and second tubular members before and aftera radial expansion and plastic deformation of the first and secondtubular members. In an exemplary embodiment, the apparatus furtherincludes means for increasing the axial tension loading capacity of thejoint between the first and second tubular members before and after aradial expansion and plastic deformation of the first and second tubularmembers. In an exemplary embodiment, the apparatus further includesmeans for increasing the axial compression and tension loading capacityof the joint between the first and second tubular members before andafter a radial expansion and plastic deformation of the first and secondtubular members. In an exemplary embodiment, the apparatus furtherincludes means for avoiding stress risers in the joint between the firstand second tubular members before and after a radial expansion andplastic deformation of the first and second tubular members. In anexemplary embodiment, the apparatus further includes means for inducingstresses at selected portions of the coupling between the first andsecond tubular members before and after a radial expansion and plasticdeformation of the first and second tubular members. In an exemplaryembodiment, the sleeve is circumferentially tensioned; and wherein thefirst and second tubular members are circumferentially compressed. In anexemplary embodiment, the means for increasing the axial compressionloading capacity of the coupling between the first and second tubularmembers before and after a radial expansion and plastic deformation ofthe first and second tubular members is circumferentially tensioned; andwherein the first and second tubular members are circumferentiallycompressed. In an exemplary embodiment, the means for increasing theaxial tension loading capacity of the coupling between the first andsecond tubular members before and after a radial expansion and plasticdeformation of the first and second tubular members is circumferentiallytensioned; and wherein the first and second tubular members arecircumferentially compressed. In an exemplary embodiment, the means forincreasing the axial compression and tension loading capacity of thecoupling between the first and second tubular members before and after aradial expansion and plastic deformation of the first and second tubularmembers is circumferentially tensioned; and wherein the first and secondtubular members are circumferentially compressed. In an exemplaryembodiment, the means for avoiding stress risers in the coupling betweenthe first and second tubular members before and after a radial expansionand plastic deformation of the first and second tubular members iscircumferentially tensioned; and wherein the first and second tubularmembers are circumferentially compressed. In an exemplary embodiment,the means for inducing stresses at selected portions of the couplingbetween the first and second tubular members before and after a radialexpansion and plastic deformation of the first and second tubularmembers is circumferentially tensioned; and wherein the first and secondtubular members are circumferentially compressed. In an exemplaryembodiment, at least a portion of the sleeve is comprised of a frangiblematerial. In an exemplary embodiment, the wall thickness of the sleeveis variable. In an exemplary embodiment, the predetermined portion ofthe apparatus has a higher ductility and a lower yield point prior tothe radial expansion and plastic deformation than after the radialexpansion and plastic deformation. In an exemplary embodiment, thepredetermined portion of the apparatus has a higher ductility prior tothe radial expansion and plastic deformation than after the radialexpansion and plastic deformation. In an exemplary embodiment, thepredetermined portion of the apparatus has a lower yield point prior tothe radial expansion and plastic deformation than after the radialexpansion and plastic deformation. In an exemplary embodiment, thepredetermined portion of the apparatus has a larger inside diameterafter the radial expansion and plastic deformation than other portionsof the tubular assembly. In an exemplary embodiment, the sleeve iscircumferentially tensioned; and wherein the first and second tubularmembers are circumferentially compressed. In an exemplary embodiment,the sleeve is circumferentially tensioned; and wherein the first andsecond tubular members are circumferentially compressed. In an exemplaryembodiment, the apparatus further includes positioning another apparatuswithin the preexisting structure in overlapping relation to theapparatus; and radially expanding and plastically deforming the otherapparatus within the preexisting structure; wherein, prior to the radialexpansion and plastic deformation of the apparatus, a predeterminedportion of the other apparatus has a lower yield point than anotherportion of the other apparatus. In an exemplary embodiment, the insidediameter of the radially expanded and plastically deformed other portionof the apparatus is equal to the inside diameter of the radiallyexpanded and plastically deformed other portion of the other apparatus.In an exemplary embodiment, the predetermined portion of the apparatuscomprises an end portion of the apparatus. In an exemplary embodiment,the predetermined portion of the apparatus comprises a plurality ofpredetermined portions of the apparatus. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a plurality of spacedapart predetermined portions of the apparatus. In an exemplaryembodiment, the other portion of the apparatus comprises an end portionof the apparatus. In an exemplary embodiment, the other portion of theapparatus comprises a plurality of other portions of the apparatus. Inan exemplary embodiment, the other portion of the apparatus comprises aplurality of spaced apart other portions of the apparatus. In anexemplary embodiment, the apparatus comprises a plurality of tubularmembers coupled to one another by corresponding tubular couplings. In anexemplary embodiment, the tubular couplings comprise the predeterminedportions of the apparatus; and wherein the tubular members comprise theother portion of the apparatus. In an exemplary embodiment, one or moreof the tubular couplings comprise the predetermined portions of theapparatus. In an exemplary embodiment, one or more of the tubularmembers comprise the predetermined portions of the apparatus. In anexemplary embodiment, the predetermined portion of the apparatus definesone or more openings. In an exemplary embodiment, one or more of theopenings comprise slots. In an exemplary embodiment, the anisotropy forthe predetermined portion of the apparatus is greater than 1. In anexemplary embodiment, the anisotropy for the predetermined portion ofthe apparatus is greater than 1. In an exemplary embodiment, the strainhardening exponent for the predetermined portion of the apparatus isgreater than 0.12. In an exemplary embodiment, the anisotropy for thepredetermined portion of the apparatus is greater than 1; and whereinthe strain hardening exponent for the predetermined portion of theapparatus is greater than 0.12. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a first steel alloycomprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu,0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point ofthe predetermined portion of the apparatus is at most about 46.9 ksiprior to the radial expansion and plastic deformation; and wherein theyield point of the predetermined portion of the apparatus is at leastabout 65.9 ksi after the radial expansion and plastic deformation. In anexemplary embodiment, the yield point of the predetermined portion ofthe apparatus after the radial expansion and plastic deformation is atleast about 40% greater than the yield point of the predeterminedportion of the apparatus prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, is about 1.48. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a second steel alloycomprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu,0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point ofthe predetermined portion of the apparatus is at most about 57.8 ksiprior to the radial expansion and plastic deformation; and wherein theyield point of the predetermined portion of the apparatus is at leastabout 74.4 ksi after the radial expansion and plastic deformation. In anexemplary embodiment, the yield point of the predetermined portion ofthe apparatus after the radial expansion and plastic deformation is atleast about 28% greater than the yield point of the predeterminedportion of the apparatus prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, is about 1.04. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a third steel alloycomprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu,0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy ofthe predetermined portion of the apparatus, prior to the radialexpansion and plastic deformation, is about 1.92. In an exemplaryembodiment, the predetermined portion of the apparatus comprises afourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S,0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, theanisotropy of the predetermined portion of the apparatus, prior to theradial expansion and plastic deformation, is about 1.34. In an exemplaryembodiment, the yield point of the predetermined portion of theapparatus is at most about 46.9 ksi prior to the radial expansion andplastic deformation; and wherein the yield point of the predeterminedportion of the apparatus is at least about 65.9 ksi after the radialexpansion and plastic deformation. In an exemplary embodiment, the yieldpoint of the predetermined portion of the apparatus after the radialexpansion and plastic deformation is at least about 40% greater than theyield point of the predetermined portion of the apparatus prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the apparatus, prior tothe radial expansion and plastic deformation, is at least about 1.48. Inan exemplary embodiment, the yield point of the predetermined portion ofthe apparatus is at most about 57.8 ksi prior to the radial expansionand plastic deformation; and wherein the yield point of thepredetermined portion of the apparatus is at least about 74.4 ksi afterthe radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of theapparatus after the radial expansion and plastic deformation is at leastabout 28% greater than the yield point of the predetermined portion ofthe apparatus prior to the radial expansion and plastic deformation. Inan exemplary embodiment, the anisotropy of the predetermined portion ofthe apparatus, prior to the radial expansion and plastic deformation, isat least about 1.04. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, is at least about 1.92. In an exemplaryembodiment, the anisotropy of the predetermined portion of theapparatus, prior to the radial expansion and plastic deformation, is atleast about 1.34. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, ranges from about 1.04 to about 1.92. In anexemplary embodiment, the yield point of the predetermined portion ofthe apparatus, prior to the radial expansion and plastic deformation,ranges from about 47.6 ksi to about 61.7 ksi. In an exemplaryembodiment, the expandability coefficient of the predetermined portionof the apparatus, prior to the radial expansion and plastic deformation,is greater than 0.12. In an exemplary embodiment, the expandabilitycoefficient of the predetermined portion of the apparatus is greaterthan the expandability coefficient of the other portion of theapparatus. In an exemplary embodiment, the apparatus comprises awellbore casing. In an exemplary embodiment, the apparatus comprises apipeline. In an exemplary embodiment, the apparatus comprises astructural support.

A radially expandable tubular member apparatus has been described thatincludes a first tubular member; a second tubular member engaged withthe first tubular member forming a joint; a sleeve overlapping andcoupling the first and second tubular members at the joint; the sleevehaving opposite tapered ends and a flange engaged in a recess formed inan adjacent tubular member; and one of the tapered ends being a surfaceformed on the flange; wherein, prior to a radial expansion and plasticdeformation of the apparatus, a predetermined portion of the apparatushas a lower yield point than another portion of the apparatus. In anexemplary embodiment, the recess includes a tapered wall in matingengagement with the tapered end formed on the flange. In an exemplaryembodiment, the sleeve includes a flange at each tapered end and eachtapered end is formed on a respective flange. In an exemplaryembodiment, each tubular member includes a recess. In an exemplaryembodiment, each flange is engaged in a respective one of the recesses.In an exemplary embodiment, each recess includes a tapered wall inmating engagement with the tapered end formed on a respective one of theflanges. In an exemplary embodiment, the predetermined portion of theapparatus has a higher ductility and a lower yield point prior to theradial expansion and plastic deformation than after the radial expansionand plastic deformation. In an exemplary embodiment, the predeterminedportion of the apparatus has a higher ductility prior to the radialexpansion and plastic deformation than after the radial expansion andplastic deformation. In an exemplary embodiment, the predeterminedportion of the apparatus has a lower yield point prior to the radialexpansion and plastic deformation than after the radial expansion andplastic deformation. In an exemplary embodiment, the predeterminedportion of the apparatus has a larger inside diameter after the radialexpansion and plastic deformation than other portions of the tubularassembly. In an exemplary embodiment, the apparatus further includespositioning another apparatus within the preexisting structure inoverlapping relation to the apparatus; and radially expanding andplastically deforming the other apparatus within the preexistingstructure; wherein, prior to the radial expansion and plasticdeformation of the apparatus, a predetermined portion of the otherapparatus has a lower yield point than another portion of the otherapparatus. In an exemplary embodiment, the inside diameter of theradially expanded and plastically deformed other portion of theapparatus is equal to the inside diameter of the radially expanded andplastically deformed other portion of the other apparatus. In anexemplary embodiment, the predetermined portion of the apparatuscomprises an end portion of the apparatus. In an exemplary embodiment,the predetermined portion of the apparatus comprises a plurality ofpredetermined portions of the apparatus. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a plurality of spacedapart predetermined portions of the apparatus. In an exemplaryembodiment, the other portion of the apparatus comprises an end portionof the apparatus. In an exemplary embodiment, the other portion of theapparatus comprises a plurality of other portions of the apparatus. Inan exemplary embodiment, the other portion of the apparatus comprises aplurality of spaced apart other portions of the apparatus. In anexemplary embodiment, the apparatus comprises a plurality of tubularmembers coupled to one another by corresponding tubular couplings. In anexemplary embodiment, the tubular couplings comprise the predeterminedportions of the apparatus; and wherein the tubular members comprise theother portion of the apparatus. In an exemplary embodiment, one or moreof the tubular couplings comprise the predetermined portions of theapparatus. In an exemplary embodiment, one or more of the tubularmembers comprise the predetermined portions of the apparatus. In anexemplary embodiment, the predetermined portion of the apparatus definesone or more openings. In an exemplary embodiment, one or more of theopenings comprise slots. In an exemplary embodiment, the anisotropy forthe predetermined portion of the apparatus is greater than 1. In anexemplary embodiment, the anisotropy for the predetermined portion ofthe apparatus is greater than 1. In an exemplary embodiment, the strainhardening exponent for the predetermined portion of the apparatus isgreater than 0.12. In an exemplary embodiment, the anisotropy for thepredetermined portion of the apparatus is greater than 1; and whereinthe strain hardening exponent for the predetermined portion of theapparatus is greater than 0.12. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a first steel alloycomprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu,0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point ofthe predetermined portion of the apparatus is at most about 46.9 ksiprior to the radial expansion and plastic deformation; and wherein theyield point of the predetermined portion of the apparatus is at leastabout 65.9 ksi after the radial expansion and plastic deformation. In anexemplary embodiment, the yield point of the predetermined portion ofthe apparatus after the radial expansion and plastic deformation is atleast about 40% greater than the yield point of the predeterminedportion of the apparatus prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, is about 1.48. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a second steel alloycomprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu,0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point ofthe predetermined portion of the apparatus is at most about 57.8 ksiprior to the radial expansion and plastic deformation; and wherein theyield point of the predetermined portion of the apparatus is at leastabout 74.4 ksi after the radial expansion and plastic deformation. In anexemplary embodiment, the yield point of the predetermined portion ofthe apparatus after the radial expansion and plastic deformation is atleast about 28% greater than the yield point of the predeterminedportion of the apparatus prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, is about 1.04. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a third steel alloycomprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu,0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy ofthe predetermined portion of the apparatus, prior to the radialexpansion and plastic deformation, is about 1.92. In an exemplaryembodiment, the predetermined portion of the apparatus comprises afourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S,0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, theanisotropy of the predetermined portion of the apparatus, prior to theradial expansion and plastic deformation, is about 1.34. In an exemplaryembodiment, the yield point of the predetermined portion of theapparatus is at most about 46.9 ksi prior to the radial expansion andplastic deformation; and wherein the yield point of the predeterminedportion of the apparatus is at least about 65.9 ksi after the radialexpansion and plastic deformation. In an exemplary embodiment, the yieldpoint of the predetermined portion of the apparatus after the radialexpansion and plastic deformation is at least about 40% greater than theyield point of the predetermined portion of the apparatus prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the apparatus, prior tothe radial expansion and plastic deformation, is at least about 1.48. Inan exemplary embodiment, the yield point of the predetermined portion ofthe apparatus is at most about 57.8 ksi prior to the radial expansionand plastic deformation; and wherein the yield point of thepredetermined portion of the apparatus is at least about 74.4 ksi afterthe radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of theapparatus after the radial expansion and plastic deformation is at leastabout 28% greater than the yield point of the predetermined portion ofthe apparatus prior to the radial expansion and plastic deformation. Inan exemplary embodiment, the anisotropy of the predetermined portion ofthe apparatus, prior to the radial expansion and plastic deformation, isat least about 1.04. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, is at least about 1.92. In an exemplaryembodiment, the anisotropy of the predetermined portion of theapparatus, prior to the radial expansion and plastic deformation, is atleast about 1.34. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, ranges from about 1.04 to about 1.92. In anexemplary embodiment, the yield point of the predetermined portion ofthe apparatus, prior to the radial expansion and plastic deformation,ranges from about 47.6 ksi to about 61.7 ksi. In an exemplaryembodiment, the expandability coefficient of the predetermined portionof the apparatus, prior to the radial expansion and plastic deformation,is greater than 0.12. In an exemplary embodiment, the expandabilitycoefficient of the predetermined portion of the apparatus is greaterthan the expandability coefficient of the other portion of theapparatus. In an exemplary embodiment, the apparatus comprises awellbore casing. In an exemplary embodiment, the apparatus comprises apipeline. In an exemplary embodiment, the apparatus comprises astructural support.

A method of joining radially expandable tubular members has beenprovided that includes: providing a first tubular member; engaging asecond tubular member with the first tubular member to form a joint;providing a sleeve; mounting the sleeve for overlapping and coupling thefirst and second tubular members at the joint; wherein the first tubularmember, the second tubular member, and the sleeve define a tubularassembly; and radially expanding and plastically deforming the tubularassembly; wherein, prior to the radial expansion and plasticdeformation, a predetermined portion of the tubular assembly has a loweryield point than another portion of the tubular assembly. In anexemplary embodiment, the carbon content of the predetermined portion ofthe tubular assembly is less than or equal to 0.12 percent; and whereinthe carbon equivalent value for the predetermined portion of the tubularassembly is less than 0.21. In an exemplary embodiment, the carboncontent of the predetermined portion of the tubular assembly is greaterthan 0.12 percent; and wherein the carbon equivalent value for thepredetermined portion of the tubular assembly is less than 0.36. In anexemplary embodiment, the method further includes: maintaining portionsof the first and second tubular member in circumferential compressionfollowing a radial expansion and plastic deformation of the first andsecond tubular members. In an exemplary embodiment, the method furtherincludes: concentrating stresses within the joint during a radialexpansion and plastic deformation of the first and second tubularmembers. In an exemplary embodiment, the method further includes:maintaining portions of the first and second tubular member incircumferential compression following a radial expansion and plasticdeformation of the first and second tubular members; and concentratingstresses within the joint during a radial expansion and plasticdeformation of the first and second tubular members. In an exemplaryembodiment, the method further includes: concentrating stresses withinthe joint. In an exemplary embodiment, concentrating stresses within thejoint comprises using the first tubular member to concentrate stresseswithin the joint. In an exemplary embodiment, concentrating stresseswithin the joint comprises using the second tubular member toconcentrate stresses within the joint. In an exemplary embodiment,concentrating stresses within the joint comprises using the sleeve toconcentrate stresses within the joint. In an exemplary embodiment,concentrating stresses within the joint comprises using the firsttubular member and the second tubular member to concentrate stresseswithin the joint. In an exemplary embodiment, concentrating stresseswithin the joint comprises using the first tubular member and the sleeveto concentrate stresses within the joint. In an exemplary embodiment,concentrating stresses within the joint comprises using the secondtubular member and the sleeve to concentrate stresses within the joint.In an exemplary embodiment, concentrating stresses within the jointcomprises using the first tubular member, the second tubular member, andthe sleeve to concentrate stresses within the joint. In an exemplaryembodiment, at least a portion of the sleeve is comprised of a frangiblematerial. In an exemplary embodiment, the sleeve comprises a variablewall thickness. In an exemplary embodiment, the method further includesmaintaining the sleeve in circumferential tension; and maintaining thefirst and second tubular members in circumferential compression. In anexemplary embodiment, the method further includes maintaining the sleevein circumferential tension; and maintaining the first and second tubularmembers in circumferential compression. In an exemplary embodiment, themethod further includes: maintaining the sleeve in circumferentialtension; and maintaining the first and second tubular members incircumferential compression. In an exemplary embodiment, the methodfurther includes: threadably coupling the first and second tubularmembers at a first location; threadably coupling the first and secondtubular members at a second location spaced apart from the firstlocation; providing a plurality of sleeves; and mounting the sleeves atspaced apart locations for overlapping and coupling the first and secondtubular members. In an exemplary embodiment, at least one of the tubularsleeves is positioned in opposing relation to the first threadedcoupling; and wherein at least one of the tubular sleeves is positionedin opposing relation to the second threaded coupling. In an exemplaryembodiment, at least one of the tubular sleeves is not positioned inopposing relation to the first and second threaded couplings. In anexemplary embodiment, the method further includes: threadably couplingthe first and second tubular members; and upsetting the threadedcoupling. In an exemplary embodiment, the first tubular member furthercomprises an annular extension extending therefrom; and wherein theflange of the sleeve defines an annular recess for receiving and matingwith the annular extension of the first tubular member. In an exemplaryembodiment, the predetermined portion of the tubular assembly has ahigher ductility and a lower yield point prior to the radial expansionand plastic deformation than after the radial expansion and plasticdeformation. In an exemplary embodiment, the predetermined portion ofthe tubular assembly has a higher ductility prior to the radialexpansion and plastic deformation than after the radial expansion andplastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a lower yield point prior to theradial expansion and plastic deformation than after the radial expansionand plastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a larger inside diameter after theradial expansion and plastic deformation than the other portion of thetubular assembly. In an exemplary embodiment, the method furtherincludes: positioning another tubular assembly within the preexistingstructure in overlapping relation to the tubular assembly; and radiallyexpanding and plastically deforming the other tubular assembly withinthe preexisting structure; wherein, prior to the radial expansion andplastic deformation of the tubular assembly, a predetermined portion ofthe other tubular assembly has a lower yield point than another portionof the other tubular assembly. In an exemplary embodiment, the insidediameter of the radially expanded and plastically deformed other portionof the tubular assembly is equal to the inside diameter of the radiallyexpanded and plastically deformed other portion of the other tubularassembly. In an exemplary embodiment, the predetermined portion of thetubular assembly comprises an end portion of the tubular assembly. In anexemplary embodiment, the predetermined portion of the tubular assemblycomprises a plurality of predetermined portions of the tubular assembly.In an exemplary embodiment, the predetermined portion of the tubularassembly comprises a plurality of spaced apart predetermined portions ofthe tubular assembly. In an exemplary embodiment, the other portion ofthe tubular assembly comprises an end portion of the tubular assembly.In an exemplary embodiment, the other portion of the tubular assemblycomprises a plurality of other portions of the tubular assembly. In anexemplary embodiment, the other portion of the tubular assemblycomprises a plurality of spaced apart other portions of the tubularassembly. In an exemplary embodiment, the tubular assembly comprises aplurality of tubular members coupled to one another by correspondingtubular couplings. In an exemplary embodiment, the tubular couplingscomprise the predetermined portions of the tubular assembly; and whereinthe tubular members comprise the other portion of the tubular assembly.In an exemplary embodiment, one or more of the tubular couplingscomprise the predetermined portions of the tubular assembly. In anexemplary embodiment, one or more of the tubular members comprise thepredetermined portions of the tubular assembly. In an exemplaryembodiment, the predetermined portion of the tubular assembly definesone or more openings. In an exemplary embodiment, one or more of theopenings comprise slots. In an exemplary embodiment, the anisotropy forthe predetermined portion of the tubular assembly is greater than 1. Inan exemplary embodiment, the anisotropy for the predetermined portion ofthe tubular assembly is greater than 1. In an exemplary embodiment, thestrain hardening exponent for the predetermined portion of the tubularassembly is greater than 0.12. In an exemplary embodiment, theanisotropy for the predetermined portion of the tubular assembly isgreater than 1; and wherein the strain hardening exponent for thepredetermined portion of the tubular assembly is greater than 0.12. Inan exemplary embodiment, the predetermined portion of the tubularassembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn,0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly is at most about 46.9 ksi prior to the radialexpansion and plastic deformation; and wherein the yield point of thepredetermined portion of the tubular assembly is at least about 65.9 ksiafter the radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly after the radial expansion and plastic deformation is at leastabout 40% greater than the yield point of the predetermined portion ofthe tubular assembly prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.48. In an exemplaryembodiment, the predetermined portion of the tubular assembly comprisesa second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S,0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment,the yield point of the predetermined portion of the tubular assembly isat most about 57.8 ksi prior to the radial expansion and plasticdeformation; and wherein the yield point of the predetermined portion ofthe tubular assembly is at least about 74.4 ksi after the radialexpansion and plastic deformation. In an exemplary embodiment, the yieldpoint of the predetermined portion of the tubular assembly after theradial expansion and plastic deformation is at least about 28% greaterthan the yield point of the predetermined portion of the tubularassembly prior to the radial expansion and plastic deformation. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is about 1.04. In an exemplary embodiment, the predetermined portion ofthe tubular assembly comprises a third steel alloy comprising: 0.08% C,0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05%Cr. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is about 1.92. In an exemplary embodiment, thepredetermined portion of the tubular assembly comprises a fourth steelalloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1%Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.34. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly is at most about 46.9 ksi prior to the radial expansion andplastic deformation; and wherein the yield point of the predeterminedportion of the tubular assembly is at least about 65.9 ksi after theradial expansion and plastic deformation. In an exemplary embodiment,the yield point of the predetermined portion of the tubular assemblyafter the radial expansion and plastic deformation is at least about 40%greater than the yield point of the predetermined portion of the tubularassembly prior to the radial expansion and plastic deformation. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is at least about 1.48. In an exemplary embodiment, the yield point ofthe predetermined portion of the tubular assembly is at most about 57.8ksi prior to the radial expansion and plastic deformation; and whereinthe yield point of the predetermined portion of the tubular assembly isat least about 74.4 ksi after the radial expansion and plasticdeformation. In an exemplary embodiment, the yield point of thepredetermined portion of the tubular assembly after the radial expansionand plastic deformation is at least about 28% greater than the yieldpoint of the predetermined portion of the tubular assembly prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is at least about1.04. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is at least about 1.92. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is at least about1.34. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, ranges from about 1.04 to about 1.92. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly, prior to the radial expansion and plasticdeformation, ranges from about 47.6 ksi to about 61.7 ksi. In anexemplary embodiment, the expandability coefficient of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is greater than 0.12. In an exemplary embodiment,the expandability coefficient of the predetermined portion of thetubular assembly is greater than the expandability coefficient of theother portion of the tubular assembly. In an exemplary embodiment, thetubular assembly comprises a wellbore casing. In an exemplaryembodiment, the tubular assembly comprises a pipeline. In an exemplaryembodiment, the tubular assembly comprises a structural support.

A method of joining radially expandable tubular members has beendescribed that includes: providing a first tubular member; engaging asecond tubular member with the first tubular member to form a joint;providing a sleeve having opposite tapered ends and a flange, one of thetapered ends being a surface formed on the flange; mounting the sleevefor overlapping and coupling the first and second tubular members at thejoint, wherein the flange is engaged in a recess formed in an adjacentone of the tubular members; wherein the first tubular member, the secondtubular member, and the sleeve define a tubular assembly; and radiallyexpanding and plastically deforming the tubular assembly; wherein, priorto the radial expansion and plastic deformation, a predetermined portionof the tubular assembly has a lower yield point than another portion ofthe tubular assembly. In an exemplary embodiment, the method furtherincludes: providing a tapered wall in the recess for mating engagementwith the tapered end formed on the flange. In an exemplary embodiment,the method further includes: providing a flange at each tapered endwherein each tapered end is formed on a respective flange. In anexemplary embodiment, the method further includes: providing a recess ineach tubular member. In an exemplary embodiment, the method furtherincludes: engaging each flange in a respective one of the recesses. Inan exemplary embodiment, the method further includes: providing atapered wall in each recess for mating engagement with the tapered endformed on a respective one of the flanges. In an exemplary embodiment,the predetermined portion of the tubular assembly has a higher ductilityand a lower yield point prior to the radial expansion and plasticdeformation than after the radial expansion and plastic deformation. Inan exemplary embodiment, the predetermined portion of the tubularassembly has a higher ductility prior to the radial expansion andplastic deformation than after the radial expansion and plasticdeformation. In an exemplary embodiment, the predetermined portion ofthe tubular assembly has a lower yield point prior to the radialexpansion and plastic deformation than after the radial expansion andplastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a larger inside diameter after theradial expansion and plastic deformation than the other portion of thetubular assembly. In an exemplary embodiment, the method furtherincludes: positioning another tubular assembly within the preexistingstructure in overlapping relation to the tubular assembly; and radiallyexpanding and plastically deforming the other tubular assembly withinthe preexisting structure; wherein, prior to the radial expansion andplastic deformation of the tubular assembly, a predetermined portion ofthe other tubular assembly has a lower yield point than another portionof the other tubular assembly. In an exemplary embodiment, the insidediameter of the radially expanded and plastically deformed other portionof the tubular assembly is equal to the inside diameter of the radiallyexpanded and plastically deformed other portion of the other tubularassembly. In an exemplary embodiment, the predetermined portion of thetubular assembly comprises an end portion of the tubular assembly. In anexemplary embodiment, the predetermined portion of the tubular assemblycomprises a plurality of predetermined portions of the tubular assembly.In an exemplary embodiment, the predetermined portion of the tubularassembly comprises a plurality of spaced apart predetermined portions ofthe tubular assembly. In an exemplary embodiment, the other portion ofthe tubular assembly comprises an end portion of the tubular assembly.In an exemplary embodiment, the other portion of the tubular assemblycomprises a plurality of other portions of the tubular assembly. In anexemplary embodiment, the other portion of the tubular assemblycomprises a plurality of spaced apart other portions of the tubularassembly. In an exemplary embodiment, the tubular assembly comprises aplurality of tubular members coupled to one another by correspondingtubular couplings. In an exemplary embodiment, the tubular couplingscomprise the predetermined portions of the tubular assembly; and whereinthe tubular members comprise the other portion of the tubular assembly.In an exemplary embodiment, one or more of the tubular couplingscomprise the predetermined portions of the tubular assembly. In anexemplary embodiment, one or more of the tubular members comprise thepredetermined portions of the tubular assembly. In an exemplaryembodiment, the predetermined portion of the tubular assembly definesone or more openings. In an exemplary embodiment, one or more of theopenings comprise slots. In an exemplary embodiment, the anisotropy forthe predetermined portion of the tubular assembly is greater than 1. Inan exemplary embodiment, the anisotropy for the predetermined portion ofthe tubular assembly is greater than 1. In an exemplary embodiment, thestrain hardening exponent for the predetermined portion of the tubularassembly is greater than 0.12. In an exemplary embodiment, theanisotropy for the predetermined portion of the tubular assembly isgreater than 1; and wherein the strain hardening exponent for thepredetermined portion of the tubular assembly is greater than 0.12. Inan exemplary embodiment, the predetermined portion of the tubularassembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn,0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly is at most about 46.9 ksi prior to the radialexpansion and plastic deformation; and wherein the yield point of thepredetermined portion of the tubular assembly is at least about 65.9 ksiafter the radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly after the radial expansion and plastic deformation is at leastabout 40% greater than the yield point of the predetermined portion ofthe tubular assembly prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.48. In an exemplaryembodiment, the predetermined portion of the tubular assembly comprisesa second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S,0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment,the yield point of the predetermined portion of the tubular assembly isat most about 57.8 ksi prior to the radial expansion and plasticdeformation; and wherein the yield point of the predetermined portion ofthe tubular assembly is at least about 74.4 ksi after the radialexpansion and plastic deformation. In an exemplary embodiment, the yieldpoint of the predetermined portion of the tubular assembly after theradial expansion and plastic deformation is at least about 28% greaterthan the yield point of the predetermined portion of the tubularassembly prior to the radial expansion and plastic deformation. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is about 1.04. In an exemplary embodiment, the predetermined portion ofthe tubular assembly comprises a third steel alloy comprising: 0.08% C,0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05%Cr. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is about 1.92. In an exemplary embodiment, thepredetermined portion of the tubular assembly comprises a fourth steelalloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1%Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.34. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly is at most about 46.9 ksi prior to the radial expansion andplastic deformation; and wherein the yield point of the predeterminedportion of the tubular assembly is at least about 65.9 ksi after theradial expansion and plastic deformation. In an exemplary embodiment,the yield point of the predetermined portion of the tubular assemblyafter the radial expansion and plastic deformation is at least about 40%greater than the yield point of the predetermined portion of the tubularassembly prior to the radial expansion and plastic deformation. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is at least about 1.48. In an exemplary embodiment, the yield point ofthe predetermined portion of the tubular assembly is at most about 57.8ksi prior to the radial expansion and plastic deformation; and whereinthe yield point of the predetermined portion of the tubular assembly isat least about 74.4 ksi after the radial expansion and plasticdeformation. In an exemplary embodiment, the yield point of thepredetermined portion of the tubular assembly after the radial expansionand plastic deformation is at least about 28% greater than the yieldpoint of the predetermined portion of the tubular assembly prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is at least about1.04. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is at least about 1.92. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is at least about1.34. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, ranges from about 1.04 to about 1.92. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly, prior to the radial expansion and plasticdeformation, ranges from about 47.6 ksi to about 61.7 ksi. In anexemplary embodiment, the expandability coefficient of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is greater than 0.12. In an exemplary embodiment,the expandability coefficient of the predetermined portion of thetubular assembly is greater than the expandability coefficient of theother portion of the tubular assembly. In an exemplary embodiment, thetubular assembly comprises a wellbore casing. In an exemplaryembodiment, the tubular assembly comprises a pipeline. In an exemplaryembodiment, the tubular assembly comprises a structural support.

An expandable tubular assembly has been described that includes a firsttubular member; a second tubular member coupled to the first tubularmember; a first threaded connection for coupling a portion of the firstand second tubular members; a second threaded connection spaced apartfrom the first threaded connection for coupling another portion of thefirst and second tubular members; a tubular sleeve coupled to andreceiving end portions of the first and second tubular members; and asealing element positioned between the first and second spaced apartthreaded connections for sealing an interface between the first andsecond tubular member; wherein the sealing element is positioned withinan annulus defined between the first and second tubular members; andwherein, prior to a radial expansion and plastic deformation of theassembly, a predetermined portion of the assembly has a lower yieldpoint than another portion of the apparatus. In an exemplary embodiment,the predetermined portion of the assembly has a higher ductility and alower yield point prior to the radial expansion and plastic deformationthan after the radial expansion and plastic deformation. In an exemplaryembodiment, the predetermined portion of the assembly has a higherductility prior to the radial expansion and plastic deformation thanafter the radial expansion and plastic deformation. In an exemplaryembodiment, the predetermined portion of the assembly has a lower yieldpoint prior to the radial expansion and plastic deformation than afterthe radial expansion and plastic deformation. In an exemplaryembodiment, the predetermined portion of the assembly has a largerinside diameter after the radial expansion and plastic deformation thanother portions of the tubular assembly. In an exemplary embodiment, theassembly further includes: positioning another assembly within thepreexisting structure in overlapping relation to the assembly; andradially expanding and plastically deforming the other assembly withinthe preexisting structure; wherein, prior to the radial expansion andplastic deformation of the assembly, a predetermined portion of theother assembly has a lower yield point than another portion of the otherassembly. In an exemplary embodiment, the inside diameter of theradially expanded and plastically deformed other portion of the assemblyis equal to the inside diameter of the radially expanded and plasticallydeformed other portion of the other assembly. In an exemplaryembodiment, the predetermined portion of the assembly comprises an endportion of the assembly. In an exemplary embodiment, the predeterminedportion of the assembly comprises a plurality of predetermined portionsof the assembly. In an exemplary embodiment, the predetermined portionof the assembly comprises a plurality of spaced apart predeterminedportions of the assembly. In an exemplary embodiment, the other portionof the assembly comprises an end portion of the assembly. In anexemplary embodiment, the other portion of the assembly comprises aplurality of other portions of the assembly. In an exemplary embodiment,the other portion of the assembly comprises a plurality of spaced apartother portions of the assembly. In an exemplary embodiment, the assemblycomprises a plurality of tubular members coupled to one another bycorresponding tubular couplings. In an exemplary embodiment, the tubularcouplings comprise the predetermined portions of the assembly; andwherein the tubular members comprise the other portion of the assembly.In an exemplary embodiment, one or more of the tubular couplingscomprise the predetermined portions of the assembly. In an exemplaryembodiment, one or more of the tubular members comprise thepredetermined portions of the assembly. In an exemplary embodiment, thepredetermined portion of the assembly defines one or more openings. Inan exemplary embodiment, one or more of the openings comprise slots. Inan exemplary embodiment, the anisotropy for the predetermined portion ofthe assembly is greater than 1. In an exemplary embodiment, theanisotropy for the predetermined portion of the assembly is greaterthan 1. In an exemplary embodiment, the strain hardening exponent forthe predetermined portion of the assembly is greater than 0.12. In anexemplary embodiment, the anisotropy for the predetermined portion ofthe assembly is greater than 1; and wherein the strain hardeningexponent for the predetermined portion of the assembly is greater than0.12. In an exemplary embodiment, the predetermined portion of theassembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn,0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In anexemplary embodiment, the yield point of the predetermined portion ofthe assembly is at most about 46.9 ksi prior to the radial expansion andplastic deformation; and wherein the yield point of the predeterminedportion of the assembly is at least about 65.9 ksi after the radialexpansion and plastic deformation. In an exemplary embodiment, the yieldpoint of the predetermined portion of the assembly after the radialexpansion and plastic deformation is at least about 40% greater than theyield point of the predetermined portion of the assembly prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the assembly, prior tothe radial expansion and plastic deformation, is about 1.48. In anexemplary embodiment, the predetermined portion of the assemblycomprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P,0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplaryembodiment, the yield point of the predetermined portion of the assemblyis at most about 57.8 ksi prior to the radial expansion and plasticdeformation; and wherein the yield point of the predetermined portion ofthe assembly is at least about 74.4 ksi after the radial expansion andplastic deformation. In an exemplary embodiment, the yield point of thepredetermined portion of the assembly after the radial expansion andplastic deformation is at least about 28% greater than the yield pointof the predetermined portion of the assembly prior to the radialexpansion and plastic deformation. In an exemplary embodiment, theanisotropy of the predetermined portion of the assembly, prior to theradial expansion and plastic deformation, is about 1.04. In an exemplaryembodiment, the predetermined portion of the assembly comprises a thirdsteel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si,0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, theanisotropy of the predetermined portion of the assembly, prior to theradial expansion and plastic deformation, is about 1.92. In an exemplaryembodiment, the predetermined portion of the assembly comprises a fourthsteel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si,9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of thepredetermined portion of the assembly, prior to the radial expansion andplastic deformation, is about 1.34. In an exemplary embodiment, theyield point of the predetermined portion of the assembly is at mostabout 46.9 ksi prior to the radial expansion and plastic deformation;and wherein the yield point of the predetermined portion of the assemblyis at least about 65.9 ksi after the radial expansion and plasticdeformation. In an exemplary embodiment, the yield point of thepredetermined portion of the assembly after the radial expansion andplastic deformation is at least about 40% greater than the yield pointof the predetermined portion of the assembly prior to the radialexpansion and plastic deformation. In an exemplary embodiment, theanisotropy of the predetermined portion of the assembly, prior to theradial expansion and plastic deformation, is at least about 1.48. In anexemplary embodiment, the yield point of the predetermined portion ofthe assembly is at most about 57.8 ksi prior to the radial expansion andplastic deformation; and wherein the yield point of the predeterminedportion of the assembly is at least about 74.4 ksi after the radialexpansion and plastic deformation. In an exemplary embodiment, the yieldpoint of the predetermined portion of the assembly after the radialexpansion and plastic deformation is at least about 28% greater than theyield point of the predetermined portion of the assembly prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the assembly, prior tothe radial expansion and plastic deformation, is at least about 1.04. Inan exemplary embodiment, the anisotropy of the predetermined portion ofthe assembly, prior to the radial expansion and plastic deformation, isat least about 1.92. In an exemplary embodiment, the anisotropy of thepredetermined portion of the assembly, prior to the radial expansion andplastic deformation, is at least about 1.34. In an exemplary embodiment,the anisotropy of the predetermined portion of the assembly, prior tothe radial expansion and plastic deformation, ranges from about 1.04 toabout 1.92. In an exemplary embodiment, the yield point of thepredetermined portion of the assembly, prior to the radial expansion andplastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In anexemplary embodiment, the expandability coefficient of the predeterminedportion of the assembly, prior to the radial expansion and plasticdeformation, is greater than 0.12. In an exemplary embodiment, theexpandability coefficient of the predetermined portion of the assemblyis greater than the expandability coefficient of the other portion ofthe assembly. In an exemplary embodiment, the assembly comprises awellbore casing. In an exemplary embodiment, the assembly comprises apipeline. In an exemplary embodiment, the assembly comprises astructural support. In an exemplary embodiment, the annulus is at leastpartially defined by an irregular surface. In an exemplary embodiment,the annulus is at least partially defined by a toothed surface. In anexemplary embodiment, the sealing element comprises an elastomericmaterial. In an exemplary embodiment, the sealing element comprises ametallic material. In an exemplary embodiment, the sealing elementcomprises an elastomeric and a metallic material.

A method of joining radially expandable tubular members is provided thatincludes providing a first tubular member; providing a second tubularmember; providing a sleeve; mounting the sleeve for overlapping andcoupling the first and second tubular members; threadably coupling thefirst and second tubular members at a first location; threadablycoupling the first and second tubular members at a second locationspaced apart from the first location; sealing an interface between thefirst and second tubular members between the first and second locationsusing a compressible sealing element, wherein the first tubular member,second tubular member, sleeve, and the sealing element define a tubularassembly; and radially expanding and plastically deforming the tubularassembly; wherein, prior to the radial expansion and plasticdeformation, a predetermined portion of the tubular assembly has a loweryield point than another portion of the tubular assembly. In anexemplary embodiment, the sealing element includes an irregular surface.In an exemplary embodiment, the sealing element includes a toothedsurface. In an exemplary embodiment, the sealing element comprises anelastomeric material. In an exemplary embodiment, the sealing elementcomprises a metallic material. In an exemplary embodiment, the sealingelement comprises an elastomeric and a metallic material. In anexemplary embodiment, the predetermined portion of the tubular assemblyhas a higher ductility and a lower yield point prior to the radialexpansion and plastic deformation than after the radial expansion andplastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a higher ductility prior to theradial expansion and plastic deformation than after the radial expansionand plastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a lower yield point prior to theradial expansion and plastic deformation than after the radial expansionand plastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a larger inside diameter after theradial expansion and plastic deformation than the other portion of thetubular assembly. In an exemplary embodiment, the method furtherincludes: positioning another tubular assembly within the preexistingstructure in overlapping relation to the tubular assembly; and radiallyexpanding and plastically deforming the other tubular assembly withinthe preexisting structure; wherein, prior to the radial expansion andplastic deformation of the tubular assembly, a predetermined portion ofthe other tubular assembly has a lower yield point than another portionof the other tubular assembly. In an exemplary embodiment, the insidediameter of the radially expanded and plastically deformed other portionof the tubular assembly is equal to the inside diameter of the radiallyexpanded and plastically deformed other portion of the other tubularassembly. In an exemplary embodiment, the predetermined portion of thetubular assembly comprises an end portion of the tubular assembly. In anexemplary embodiment, the predetermined portion of the tubular assemblycomprises a plurality of predetermined portions of the tubular assembly.In an exemplary embodiment, the predetermined portion of the tubularassembly comprises a plurality of spaced apart predetermined portions ofthe tubular assembly. In an exemplary embodiment, the other portion ofthe tubular assembly comprises an end portion of the tubular assembly.In an exemplary embodiment, the other portion of the tubular assemblycomprises a plurality of other portions of the tubular assembly. In anexemplary embodiment, the other portion of the tubular assemblycomprises a plurality of spaced apart other portions of the tubularassembly. In an exemplary embodiment, the tubular assembly comprises aplurality of tubular members coupled to one another by correspondingtubular couplings. In an exemplary embodiment, the tubular couplingscomprise the predetermined portions of the tubular assembly; and whereinthe tubular members comprise the other portion of the tubular assembly.In an exemplary embodiment, one or more of the tubular couplingscomprise the predetermined portions of the tubular assembly. In anexemplary embodiment, one or more of the tubular members comprise thepredetermined portions of the tubular assembly. In an exemplaryembodiment, the predetermined portion of the tubular assembly definesone or more openings. In an exemplary embodiment, one or more of theopenings comprise slots. In an exemplary embodiment, the anisotropy forthe predetermined portion of the tubular assembly is greater than 1. Inan exemplary embodiment, the anisotropy for the predetermined portion ofthe tubular assembly is greater than 1. In an exemplary embodiment, thestrain hardening exponent for the predetermined portion of the tubularassembly is greater than 0.12. In an exemplary embodiment, theanisotropy for the predetermined portion of the tubular assembly isgreater than 1; and wherein the strain hardening exponent for thepredetermined portion of the tubular assembly is greater than 0.12. Inan exemplary embodiment, the predetermined portion of the tubularassembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn,0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly is at most about 46.9 ksi prior to the radialexpansion and plastic deformation; and wherein the yield point of thepredetermined portion of the tubular assembly is at least about 65.9 ksiafter the radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly after the radial expansion and plastic deformation is at leastabout 40% greater than the yield point of the predetermined portion ofthe tubular assembly prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.48. In an exemplaryembodiment, the predetermined portion of the tubular assembly comprisesa second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S,0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment,the yield point of the predetermined portion of the tubular assembly isat most about 57.8 ksi prior to the radial expansion and plasticdeformation; and wherein the yield point of the predetermined portion ofthe tubular assembly is at least about 74.4 ksi after the radialexpansion and plastic deformation. In an exemplary embodiment, the yieldpoint of the predetermined portion of the tubular assembly after theradial expansion and plastic deformation is at least about 28% greaterthan the yield point of the predetermined portion of the tubularassembly prior to the radial expansion and plastic deformation. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is about 1.04. In an exemplary embodiment, the predetermined portion ofthe tubular assembly comprises a third steel alloy comprising: 0.08% C,0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05%Cr. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is about 1.92. In an exemplary embodiment, thepredetermined portion of the tubular assembly comprises a fourth steelalloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1%Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.34. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly is at most about 46.9 ksi prior to the radial expansion andplastic deformation; and wherein the yield point of the predeterminedportion of the tubular assembly is at least about 65.9 ksi after theradial expansion and plastic deformation. In an exemplary embodiment,the yield point of the predetermined portion of the tubular assemblyafter the radial expansion and plastic deformation is at least about 40%greater than the yield point of the predetermined portion of the tubularassembly prior to the radial expansion and plastic deformation. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is at least about 1.48. In an exemplary embodiment, the yield point ofthe predetermined portion of the tubular assembly is at most about 57.8ksi prior to the radial expansion and plastic deformation; and whereinthe yield point of the predetermined portion of the tubular assembly isat least about 74.4 ksi after the radial expansion and plasticdeformation. In an exemplary embodiment, the yield point of thepredetermined portion of the tubular assembly after the radial expansionand plastic deformation is at least about 28% greater than the yieldpoint of the predetermined portion of the tubular assembly prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is at least about1.04. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is at least about 1.92. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is at least about1.34. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, ranges from about 1.04 to about 1.92. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly, prior to the radial expansion and plasticdeformation, ranges from about 47.6 ksi to about 61.7 ksi. In anexemplary embodiment, the expandability coefficient of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is greater than 0.12. In an exemplary embodiment,the expandability coefficient of the predetermined portion of thetubular assembly is greater than the expandability coefficient of theother portion of the tubular assembly. In an exemplary embodiment, thetubular assembly comprises a wellbore casing. In an exemplaryembodiment, the tubular assembly comprises a pipeline. In an exemplaryembodiment, the tubular assembly comprises a structural support. In anexemplary embodiment, the sleeve comprises: a plurality of spaced aparttubular sleeves coupled to and receiving end portions of the first andsecond tubular members. In an exemplary embodiment, the first tubularmember comprises a first threaded connection; wherein the second tubularmember comprises a second threaded connection; wherein the first andsecond threaded connections are coupled to one another; wherein at leastone of the tubular sleeves is positioned in opposing relation to thefirst threaded connection; and wherein at least one of the tubularsleeves is positioned in opposing relation to the second threadedconnection. In an exemplary embodiment, the first tubular membercomprises a first threaded connection; wherein the second tubular membercomprises a second threaded connection; wherein the first and secondthreaded connections are coupled to one another; and wherein at leastone of the tubular sleeves is not positioned in opposing relation to thefirst and second threaded connections. In an exemplary embodiment, thecarbon content of the tubular member is less than or equal to 0.12percent; and wherein the carbon equivalent value for the tubular memberis less than 0.21. In an exemplary embodiment, the tubular membercomprises a wellbore casing.

An expandable tubular member has been described, wherein the carboncontent of the tubular member is greater than 0.12 percent; and whereinthe carbon equivalent value for the tubular member is less than 0.36. Inan exemplary embodiment, the tubular member comprises a wellbore casing.

A method of selecting tubular members for radial expansion and plasticdeformation has been described that includes: selecting a tubular memberfrom a collection of tubular member; determining a carbon content of theselected tubular member; determining a carbon equivalent value for theselected tubular member; and if the carbon content of the selectedtubular member is less than or equal to 0.12 percent and the carbonequivalent value for the selected tubular member is less than 0.21, thendetermining that the selected tubular member is suitable for radialexpansion and plastic deformation.

A method of selecting tubular members for radial expansion and plasticdeformation has been described that includes: selecting a tubular memberfrom a collection of tubular member; determining a carbon content of theselected tubular member; determining a carbon equivalent value for theselected tubular member; and if the carbon content of the selectedtubular member is greater than 0.12 percent and the carbon equivalentvalue for the selected tubular member is less than 0.36, thendetermining that the selected tubular member is suitable for radialexpansion and plastic deformation.

An expandable tubular member has been described that includes: a tubularbody; wherein a yield point of an inner tubular portion of the tubularbody is less than a yield point of an outer tubular portion of thetubular body. In an exemplary embodiment, the yield point of the innertubular portion of the tubular body varies as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the inner tubular portion of the tubular body varies in anlinear fashion as a function of the radial position within the tubularbody. In an exemplary embodiment, the yield point of the inner tubularportion of the tubular body varies in an non-linear fashion as afunction of the radial position within the tubular body. In an exemplaryembodiment, the yield point of the outer tubular portion of the tubularbody varies as a function of the radial position within the tubularbody. In an exemplary embodiment, the yield point of the outer tubularportion of the tubular body varies in an linear fashion as a function ofthe radial position within the tubular body. In an exemplary embodiment,the yield point of the outer tubular portion of the tubular body variesin an non-linear fashion as a function of the radial position within thetubular body. In an exemplary embodiment, the yield point of the innertubular portion of the tubular body varies as a function of the radialposition within the tubular body; and wherein the yield point of theouter tubular portion of the tubular body varies as a function of theradial position within the tubular body. In an exemplary embodiment, theyield point of the inner tubular portion of the tubular body varies in alinear fashion as a function of the radial position within the tubularbody; and wherein the yield point of the outer tubular portion of thetubular body varies in a linear fashion as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the inner tubular portion of the tubular body varies in alinear fashion as a function of the radial position within the tubularbody; and wherein the yield point of the outer tubular portion of thetubular body varies in a non-linear fashion as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the inner tubular portion of the tubular body varies in anon-linear fashion as a function of the radial position within thetubular body; and wherein the yield point of the outer tubular portionof the tubular body varies in a linear fashion as a function of theradial position within the tubular body. In an exemplary embodiment, theyield point of the inner tubular portion of the tubular body varies in anon-linear fashion as a function of the radial position within thetubular body; and wherein the yield point of the outer tubular portionof the tubular body varies in a non-linear fashion as a function of theradial position within the tubular body. In an exemplary embodiment, therate of change of the yield point of the inner tubular portion of thetubular body is different than the rate of change of the yield point ofthe outer tubular portion of the tubular body. In an exemplaryembodiment, the rate of change of the yield point of the inner tubularportion of the tubular body is different than the rate of change of theyield point of the outer tubular portion of the tubular body.

A method of manufacturing an expandable tubular member has beendescribed that includes: providing a tubular member; heat treating thetubular member; and quenching the tubular member; wherein following thequenching, the tubular member comprises a microstructure comprising ahard phase structure and a soft phase structure. In an exemplaryembodiment, the provided tubular member comprises, by weight percentage,0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni,0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti. In an exemplaryembodiment, the provided tubular member comprises, by weight percentage,0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni,0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti. In an exemplaryembodiment, the provided tubular member comprises, by weight percentage,0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu, 0.05% Ni,0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti. In an exemplaryembodiment, the provided tubular member comprises a microstructurecomprising one or more of the following: martensite, pearlite, vanadiumcarbide, nickel carbide, or titanium carbide. In an exemplaryembodiment, the provided tubular member comprises a microstructurecomprising one or more of the following: pearlite or pearlite striation.In an exemplary embodiment, the provided tubular member comprises amicrostructure comprising one or more of the following: grain pearlite,widmanstatten martensite, vanadium carbide, nickel carbide, or titaniumcarbide. In an exemplary embodiment, the heat treating comprises heatingthe provided tubular member for about 10 minutes at 790° C. In anexemplary embodiment, the quenching comprises quenching the heat treatedtubular member in water. In an exemplary embodiment, following thequenching, the tubular member comprises a microstructure comprising oneor more of the following: ferrite, grain pearlite, or martensite. In anexemplary embodiment, following the quenching, the tubular membercomprises a microstructure comprising one or more of the following:ferrite, martensite, or bainite. In an exemplary embodiment, followingthe quenching, the tubular member comprises a microstructure comprisingone or more of the following: bainite, pearlite, or ferrite. In anexemplary embodiment, following the quenching, the tubular membercomprises a yield strength of about 67 ksi and a tensile strength ofabout 95 ksi. In an exemplary embodiment, following the quenching, thetubular member comprises a yield strength of about 82 ksi and a tensilestrength of about 130 ksi. In an exemplary embodiment, following thequenching, the tubular member comprises a yield strength of about 60 ksiand a tensile strength of about 97 ksi. In an exemplary embodiment, themethod further includes: positioning the quenched tubular member withina preexisting structure; and radially expanding and plasticallydeforming the tubular member within the preexisting structure.

An expansion device for radially expanding and plastically deforming atubular member has been described that includes: an elongated basemember and an adjustable expansion assembly moveably coupled to theelongated base member, the adjustable expansion assembly comprising aplurality of expansion segment operable to expand the adjustableexpansion assembly in diameter, wherein throughout the expansion atleast a portion of the expansion segments overlap in the circumferentialdirection. In an exemplary embodiment, the elongated base member definesa passageway operable to allow a fluid to pass through the elongatedbase member. In an exemplary embodiment, the elongated base membercomprises a conical member, wherein the adjustable expansion assembly isoperable to expand by translating along a surface of the conical member.In an exemplary embodiment, the adjustable expansion assembly comprisesa lubrication system operable to provide lubrication to a surface of theadjustable expansion assembly. In an exemplary embodiment, an actuatoris coupled to the base member and the adjustable expansion assembly, theactuator operable to expand the adjustable expansion assembly. In anexemplary embodiment, a plurality of pivotal couplings are positionedbetween the actuator and the plurality of expansion segments. In anexemplary embodiment, the actuator is chosen from the group consistingof a hydraulic actuator, an electrical actuator, a mechanical actuator,and combinations thereof. In an exemplary embodiment, the adjustableexpansion assembly comprises a means for creating a pressure drop acrossthe adjustable expansion assembly sufficient to overcome the forcesnecessary to radially expand and plastically deform a tubular memberwhen a pressurized hydraulic fluid engages a surface of the adjustableexpansion assembly. In an exemplary embodiment, the means comprises anengagement between the adjustable expansion assembly and the inner wallof a tubular member. In an exemplary embodiment, the means comprises apreliminary expansion member. In an exemplary embodiment, thepreliminary expansion member is operable to expand the tubular memberbetween 1-10% the desired expansion. In an exemplary embodiment, thepreliminary expansion member comprises a lubrication system operable toprovide lubrication between the preliminary expansion member and aninner surface of a tubular member. In an exemplary embodiment, a supportmember is coupled to the base member, the support member operable tosecure to the inner surface of a tubular member and an actuator iscoupled to the support member and adapted to displace the device axiallythrough the tubular member. In an exemplary embodiment, the actuator isselected from the group consisting of a hydraulic actuator, anelectrical actuator, a mechanical actuator, and combinations thereof. Inan exemplary embodiment, the base member is coupled to a tubularcoupling. In an exemplary embodiment, the device is positioned within atubular member. In an exemplary embodiment, the base member comprises aconical flange along its length. In an exemplary embodiment, theadjustable expansion assembly is moveably coupled to the conical flange.In an exemplary embodiment, the adjustable expansion assembly comprisesa means for preventing axial grooves in a tubular member when theexpansion device is displaced axially through the tubular member.

An expansion device for radially expanding and plastically deforming atubular member has been described that includes: an elongated basemember comprising a conical member along the length thereof, an actuatorcoupled to the base member and a plurality of expansion segments coupledto the conical member and the actuator, whereby, upon actuation, theplurality of expansion segments are operable to expand in diameter bydisplacing along the conical member, wherein throughout the expansion atleast a portion of the plurality of expansion segments overlap in thecircumferential direction. In an exemplary embodiment, the elongatedbase member defines a passageway operable to allow a fluid to passthrough the elongated base member. In an exemplary embodiment, theactuator is selected from the group consisting of a hydraulic actuator,an electrical actuator, a mechanical actuator, and combinations thereof.In an exemplary embodiment, a lubrication system is provided which isoperable to provide a lubricant between the plurality of expansionsegments and an inner surface of a tubular member. In an exemplaryembodiment, a plurality of pivotal couplings are included for couplingthe actuator to the plurality of expansion segments. In an exemplaryembodiment, the plurality of expansion segments comprise a means forcreating a pressure drop across the adjustable expansion assemblysufficient to overcome the forces necessary to radially expand andplastically deform a tubular member when a pressurized hydraulic fluidengages a surface of the plurality of expansion segments. In anexemplary embodiment, the base member is coupled to a tubular coupling.In an exemplary embodiment, the device is positioned within a tubularmember. In an exemplary embodiment, the plurality of expansion segmentscomprise a means for preventing axial grooves in a tubular member whenthe expansion device is displaced axially through the tubular member.

An expansion device for radially expanding and plastically deforming atubular member has been described that includes: an elongated basemember comprising a conical member along the length thereof, apreliminary expansion member coupled to the elongated base member, anactuator coupled to the base member and a plurality of expansionsegments coupled to the conical member and the actuator, whereby, uponactuation, the plurality of expansion segments are operable to expand indiameter by displacing along the conical member, wherein throughout theexpansion at least a portion of the plurality of expansion segmentsoverlap in the circumferential direction. In an exemplary embodiment,the elongated base member defines a passageway operable to allow a fluidto pass through the elongated base member. In an exemplary embodiment,the preliminary expansion member comprises a lubrication system operableto provide lubrication between the preliminary expansion member and aninner surface of a tubular member. In an exemplary embodiment, theactuator is selected from the group consisting of a hydraulic actuator,an electrical actuator, a mechanical actuator, and combinations thereof.In an exemplary embodiment, a lubrication system is provided which isoperable to provide a lubricant between the plurality of expansionsegments and an inner surface of a tubular member. In an exemplaryembodiment, a plurality of pivotal couplings are provided for couplingthe actuator to the plurality of expansion segments. In an exemplaryembodiment, the preliminary expansion member is operable to create apressure drop across the preliminary expansion member sufficient toovercome the forces necessary to radially expand and plastically deforma tubular member when a pressurized hydraulic fluid engages a surface ofthe preliminary expansion member. In an exemplary embodiment, the basemember is coupled to a tubular coupling. In an exemplary embodiment, thedevice is positioned within a tubular member. In an exemplaryembodiment, the plurality of expansion segments comprise a means forpreventing axial grooves in a tubular member when the expansion deviceis displaced axially through the tubular member.

An expansion device for radially expanding and plastically deforming atubular member has been described that includes: an elongated basemember comprising a conical member along the length thereof, an firstactuator coupled to the base member, a plurality of expansion segmentscoupled to the conical member and the actuator, whereby, upon actuation,the plurality of expansion segments are operable to expand in diameterby displacing along the conical member, wherein throughout the expansionat least a portion of the plurality of expansion segments overlap in thecircumferential direction, a support member coupled to the base member,the support member operable to secure to the inner surface of a tubularmember and a second actuator coupled to the base and the support memberand adapted to displace the device axially through the tubular member.In an exemplary embodiment, the elongated base member defines apassageway operable to allow a fluid to pass through the elongated basemember. In an exemplary embodiment, the first actuator is selected fromthe group consisting of a hydraulic actuator, an electrical actuator, amechanical actuator, and combinations thereof. In an exemplaryembodiment, the second actuator is selected from the group consisting ofa hydraulic actuator, an electrical actuator, a mechanical actuator, andcombinations thereof. In an exemplary embodiment, a lubrication systemis provided which is operable to provide a lubricant between theplurality of expansion segments and an inner surface of a tubularmember. In an exemplary embodiment, a plurality of pivotal couplings areprovided for coupling the first actuator to the plurality of expansionsegments. In an exemplary embodiment, the plurality of expansionsegments comprise a means for creating a pressure drop across theadjustable expansion assembly sufficient to overcome the forcesnecessary to radially expand and plastically deform a tubular memberwhen a pressurized hydraulic fluid engages a surface of the plurality ofexpansion segments. In an exemplary embodiment, the base member iscoupled to a tubular coupling. In an exemplary embodiment, the device ispositioned within a tubular member. In an exemplary embodiment, theplurality of expansion segments comprise a means for preventing axialgrooves in a tubular member when the expansion device is displacedaxially through the tubular member.

A method for radially expanding and plastically deforming a tubularmember has been described that includes: providing a tubular member, thetubular member defining a passage therein, locating an expansion devicein the passageway defined by the tubular member, the expansion devicecomprising an adjustable expansion assembly, the adjustable expansionassembly comprising a plurality of expansion segments operable to expandthe adjustable expansion assembly in diameter, wherein throughout theexpansion at least a portion of the plurality of expansion segmentsoverlap in the circumferential direction, expanding the adjustableexpansion assembly, displacing the expansion device along a longitudinalaxis through the tubular member and radially expanding and plasticallydeforming the tubular member along the longitudinal axis. In anexemplary embodiment, the method further includes creating a pressuredrop across the expansion sufficient to overcome the forces necessary toradially expand and plastically deform a tubular member by providing ahydraulic fluid in the tubular member.

A method for radially expanding and plastically deforming a tubularmember has been described that includes: providing a tubular member, thetubular member defining a passageway therein, locating an expansiondevice in the passageway defined by the tubular member, the expansiondevice comprising an adjustable expansion assembly and a preliminaryexpansion member, the adjustable expansion assembly comprising aplurality of expansion segments operable to expand the adjustableexpansion assembly in diameter, wherein throughout the expansion atleast a portion of the plurality of expansion segments overlap in thecircumferential direction, expanding the adjustable expansion assembly,creating a pressure drop across the preliminary expansion member toovercome the forces necessary to radially expand and plastically deforma tubular member, displacing the expansion device along a longitudinalaxis through the tubular member, and radially expanding and plasticallydeforming the tubular member along the longitudinal axis.

An expansion device for expanding a tubular member has been describedthat includes: an elongated base member, an expansion assembly moveablycoupled to the elongated base member, the expansion assembly comprisinga plurality of means for expanding the expansion assembly and means foroverlapping the plurality of means for expanding the expansion assemblyin a circumferential direction throughout expansion. In an exemplaryembodiment, means is provided for providing lubrication between theexpansion assembly and an inner surface of a tubular member. In anexemplary embodiment, means is provided for creating a pressure dropacross the expansion assembly sufficient to overcome the forcesnecessary to radially expand and plastically deform a tubular memberwhen a pressurized hydraulic fluid engages a surface of the expansionassembly. In an exemplary embodiment, means is provided for preventingaxial grooves in a tubular member when the expansion device is displacedaxially through the tubular member.

A method for manufacturing an expandable member used to complete astructure by radially expanding and plastically deforming the expandablemember has been described that includes forming the expandable memberfrom a steel alloy comprising a charpy energy of at least about 90ft-lbs.

An expandable member for use in completing a structure by radiallyexpanding and plastically deforming the expandable member has beendescribed that includes a steel alloy comprising a charpy energy of atleast about 90 ft-lbs.

A structural completion positioned within a structure has been describedthat includes one or more radially expanded and plastically deformedexpandable members positioned within the structure; wherein one or moreof the radially expanded and plastically deformed expandable members arefabricated from a steel alloy comprising a charpy energy of at leastabout 90 ft-lbs.

A method for manufacturing an expandable member used to complete astructure by radially expanding and plastically deforming the expandablemember has been described that includes forming the expandable memberfrom a steel alloy comprising a weight percentage of carbon of less thanabout 0.08%.

An expandable member for use in completing a wellbore by radiallyexpanding and plastically deforming the expandable member at a downholelocation in the wellbore has been described that includes a steel alloycomprising a weight percentage of carbon of less than about 0.08%.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members positionedwithin the wellbore; wherein one or more of the radially expanded andplastically deformed expandable members are fabricated from a steelalloy comprising a weight percentage of carbon of less than about 0.08%.

A method for manufacturing an expandable member used to complete astructure by radially expanding and plastically deforming the expandablemember has been described that includes forming the expandable memberfrom a steel alloy comprising a weight percentage of carbon of less thanabout 0.20% and a charpy V-notch impact toughness of at least about 6joules.

An expandable member for use in completing a structure by radiallyexpanding and plastically deforming the expandable member has beendescribed that includes a steel alloy comprising a weight percentage ofcarbon of less than about 0.20% and a charpy V-notch impact toughness ofat least about 6 joules.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members; whereinone or more of the radially expanded and plastically deformed expandablemembers are fabricated from a steel alloy comprising a weight percentageof carbon of less than about 0.20% and a charpy V-notch impact toughnessof at least about 6 joules.

A method for manufacturing an expandable member used to complete astructure by radially expanding and plastically deforming the expandablemember has been described that includes forming the expandable memberfrom a steel alloy comprising the following ranges of weightpercentages: C, from about 0.002 to about 0.08; Si, from about 0.009 toabout 0.30; Mn, from about 0.10 to about 1.92; P, from about 0.004 toabout 0.07; S, from about 0.0008 to about 0.006; Al, up to about 0.04;N, up to about 0.01; Cu, up to about 0.3; Cr, up to about 0.5; Ni, up toabout 18; Nb, up to about 0.12; Ti, up to about 0.6; Co, up to about 9;and Mo, up to about 5.

An expandable member for use in completing a structure by radiallyexpanding and plastically deforming the expandable member has beendescribed that includes a steel alloy comprising the following ranges ofweight percentages: C, from about 0.002 to about 0.08; Si, from about0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P, from about0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al, up toabout 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up to about0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to about 0.6; Co,up to about 9; and Mo, up to about 5.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members; whereinone or more of the radially expanded and plastically deformed expandablemembers are fabricated from a steel alloy comprising the followingranges of weight percentages: C, from about 0.002 to about 0.08; Si,from about 0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P,from about 0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al,up to about 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up toabout 0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to about0.6; Co, up to about 9; and Mo, up to about 5.

A method for manufacturing an expandable tubular member used to completea structure by radially expanding and plastically deforming theexpandable member has been described that includes forming theexpandable tubular member with a ratio of the of an outside diameter ofthe expandable tubular member to a wall thickness of the expandabletubular member ranging from about 12 to 22.

An expandable member for use in completing a structure by radiallyexpanding and plastically deforming the expandable member has beendescribed that includes an expandable tubular member with a ratio of theof an outside diameter of the expandable tubular member to a wallthickness of the expandable tubular member ranging from about 12 to 22.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members positionedwithin the structure; wherein one or more of the radially expanded andplastically deformed expandable members are fabricated from anexpandable tubular member with a ratio of the of an outside diameter ofthe expandable tubular member to a wall thickness of the expandabletubular member ranging from about 12 to 22.

A method of constructing a structure has been described that includesradially expanding and plastically deforming an expandable member;wherein an outer portion of the wall thickness of the radially expandedand plastically deformed expandable member comprises tensile residualstresses.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members; whereinan outer portion of the wall thickness of one or more of the radiallyexpanded and plastically deformed expandable members comprises tensileresidual stresses.

A method of constructing a structure using an expandable tubular memberhas been described that includes strain aging the expandable member; andthen radially expanding and plastically deforming the expandable member.

A method for manufacturing a tubular member used to complete a wellboreby radially expanding the tubular member at a downhole location in thewellbore has been described that includes forming a steel alloycomprising a concentration of carbon between approximately 0.002% and0.08% by weight of the steel alloy.

A method of increasing a collapse strength of a tubular member after aradial expansion and plastic deformation of the tubular member using anexpansion device has been described that includes reducing a coefficientof friction between the tubular member and the expansion device duringthe radial expansion and plastic deformation of the tubular member; andreducing a ratio of a diameter of the tubular member to a wall thicknessof the tubular member. In an exemplary embodiment, the coefficient offriction is less than 0.075. In an exemplary embodiment, the ratio ofthe diameter of the tubular member to a wall thickness of the tubularmember is less than 21.6. In an exemplary embodiment, the collapsestrength of a tubular member after the radial expansion and plasticdeformation of the tubular member using an expansion device is greaterthan 5000 ksi.

A system for radially expanding and plastically deforming a tubularmember has been described that includes a tubular member, and anexpansion device positioned within the tubular member, wherein thecoefficient of friction between the tubular member and the expansiondevice is less than 0.075, and wherein the ratio of the diameter of thetubular member to a wall thickness of the tubular member is less than21.6.

A method of radially expanding and plastically deforming a tubularmember using an expansion device has been described that includesquenching and tempering the tubular member; positioning the tubularmember within a preexisting structure; and radially expanding andplastically deforming the tubular member. In an exemplary embodiment,the yield strength of the tubular member ranges from about 76.8 ksi to88.8 ksi. In an exemplary embodiment, the ratio of the yield strength tothe tensile strength of the tubular member ranges from about 0.82 to0.86. In an exemplary embodiment, the longitudinal elongation of thetubular member prior to failure ranges from about 14.8% to 22.0%. In anexemplary embodiment, the width reduction of the tubular member prior tofailure ranges from about 32% to 44.0%. In an exemplary embodiment, thewidth thickness reduction of the tubular member prior to failure rangesfrom about 41.0% to 45%. In an exemplary embodiment, the anisotropy ofthe tubular member ranges from about 0.65 to 1.03. In an exemplaryembodiment, the absorbed energy in the longitudinal direction of thetubular member ranges from about 125 to 145 ft-lbs. In an exemplaryembodiment, the absorbed energy in the transverse direction of thetubular member ranges from about 59 to 59 ft-lbs. In an exemplaryembodiment, the absorbed energy in a welded portion of the tubularmember ranges from about 174 to 176 ft-lbs. In an exemplary embodiment,a flared expansion of an end of tubular member ranged from about 42 to52%. In an exemplary embodiment, the tubular member comprises, by weightpercentage: 0.27 C; 0.14 Si; 1.28 Mn; 0.009 P; 0.005 S; and 0.14 Cr. Inan exemplary embodiment, the quenching of the tubular member is providedat about 970 C; and the tempering the tubular member is provided atabout 670 C.

A radially expandable and plastically deformable tubular member has beendescribed that includes a yield strength ranging from about 76.8 ksi to88.8 ksi, a ratio of the yield strength to a tensile strength of thetubular member ranging from about 0.82 to 0.86, a longitudinalelongation of the tubular member prior to failure ranging from about14.8% to 22.0%, a width reduction of the tubular member prior to failureranging from about 32% to 44.0%, a width thickness reduction of thetubular member prior to failure ranges from about 41.0% to 45%, and ananisotropy of the tubular member ranges from about 0.65 to 1.03. In anexemplary embodiment, an absorbed energy in the longitudinal directionof the tubular member ranges from about 125 to 145 ft-lbs. In anexemplary embodiment, the absorbed energy in the transverse direction ofthe tubular member ranges from about 59 to 59 ft-lbs. In an exemplaryembodiment, the absorbed energy in a welded portion of the tubularmember ranges from about 174 to 176 ft-lbs. In an exemplary embodiment,a flared expansion of an end of tubular member ranged from about 42 to52%. In an exemplary embodiment, the tubular member comprises, by weightpercentage: 0.27 C; 0.14 Si; 1.28 Mn; 0.009 P; 0.005 S; and 0.14 Cr.

A radially expandable and plastically deformable tubular member has beendescribed that includes: a yield strength ranging from about 40.0 ksi to100.0 ksi; a ratio of the yield strength to a tensile strength of thetubular member ranging from about 0.40 to 0.85; a longitudinalelongation of the tubular member prior to failure ranging from at leastabout 22.0 to 35.0%; a width reduction of the tubular member prior tofailure ranging from at least about 30.0% to 45.0%; a width thicknessreduction of the tubular member prior to failure ranges from at leastabout 30.0% to 45.0%; and an anisotropy of the tubular member rangesfrom at least about 0.65 to 1.50. In an exemplary embodiment, anabsorbed energy in the longitudinal direction of the tubular member isat least about 80 ft-lbs. In an exemplary embodiment, the absorbedenergy in the transverse direction of the tubular member is at leastabout 60 ft-lbs. In an exemplary embodiment, the absorbed energy in awelded portion of the tubular member is at least about 60 ft-lbs. In anexemplary embodiment, a flared expansion of an end of tubular memberranges from at least about 45 to 75%.

A method of manufacturing a tubular member has been described thatincludes fabricating a tubular member; positioning the tubular memberwithin a preexisting structure; radially expanding and plasticallydeforming the tubular member within the preexisting structure; andbaking the tubular member within the preexisting structure. In anexemplary embodiment, the preexisting structure comprises a wellbore. Inan exemplary embodiment, the fabricated tubular member comprises a dualphase steel pipe. In an exemplary embodiment, the fabricated tubularmember comprises a microstructure comprising about 15 to 30% martensite;and ferrite. In an exemplary embodiment, the fabricated tubular membercomprises, by weight percentage: 0.1 C; 1.2 Mn; and 0.3 Si. In anexemplary embodiment, the fabricated tubular member comprises a TRIPsteel pipe. In an exemplary embodiment, fabricating the tubular membercomprises: cold rolling the tubular member; and inter critical annealingthe tubular member. In an exemplary embodiment, the fabricated tubularmember comprises a dual phase steel pipe. In an exemplary embodiment,prior to the cold rolling, the fabricated tubular member comprises amicrostructure comprising ferrite and pearlite. In an exemplaryembodiment, the inter critical annealing is performed at about 750 C. Inan exemplary embodiment, after the inter critical annealing, thefabricated tubular member comprises a microstructure comprising ferriteand at least one of pearlite and austentite. In an exemplary embodiment,the method further comprising: cooling the tubular member after theinter critical annealing. In an exemplary embodiment, after the cooling,the tubular member comprises a microstructure comprising martensite. Inan exemplary embodiment, the baking is provided at about 100 C to 250 C.In an exemplary embodiment, following at least a portion of the baking,the tubular member comprises a bake-hardened portion. In an exemplaryembodiment, following at least a portion of the baking, the tubularmember comprises a stress-relieved portion. In an exemplary embodiment,following at least a portion of the baking, the tubular member comprisesa bake-hardened portion and a stress-relieved portion. In an exemplaryembodiment, the cold rolling comprises: allowing the tubular member tocool over time from a first temperature to a second temperature along atemperature versus time curve; and at a plurality of stages along thecurve, deforming the tubular member. In an exemplary embodiment, at afirst stage along the curve, insoluble precipitates within the tubularmember retard austentite growth. In an exemplary embodiment, at a firststage along the curve, deformation of the tubular member promotesprecipitation. In an exemplary embodiment, at a second stage along thecurve, insoluble precipitates within the tubular member inhibitrecrystallization. In an exemplary embodiment, at a second stage alongthe curve, austentite grains are conditioned.

It is understood that variations may be made in the foregoing withoutdeparting from the scope of the invention. For example, the teachings ofthe present illustrative embodiments may be used to provide a wellborecasing, a pipeline, or a structural support. Furthermore, the elementsand teachings of the various illustrative embodiments may be combined inwhole or in part in some or all of the illustrative embodiments. Inaddition, one or more of the elements and teachings of the variousillustrative embodiments may be omitted, at least in part, and/orcombined, at least in part, with one or more of the other elements andteachings of the various illustrative embodiments.

Although illustrative embodiments of the invention have been shown anddescribed, a wide range of modification, changes and substitution iscontemplated in the foregoing disclosure. In some instances, somefeatures of the present invention may be employed without acorresponding use of the other features. Accordingly, it is appropriatethat the appended claims be construed broadly and in a manner consistentwith the scope of the invention.

1. A method of forming a tubular liner within a preexisting structure,comprising: positioning a tubular assembly within the preexistingstructure; and radially expanding and plastically deforming the tubularassembly within the preexisting structure; wherein, prior to the radialexpansion and plastic deformation of the tubular assembly, apredetermined portion of the tubular assembly has a lower yield pointthan another portion of the tubular assembly. 2-118. (canceled)
 119. Anexpandable tubular member, wherein the expandability coefficient of theexpandable tubular member is greater than the expandability coefficientof another portion of the expandable tubular member. 120-122. (canceled)123. An expandable tubular member, wherein the tubular member has ahigher ductility and a lower yield point prior to a radial expansion andplastic deformation than after the radial expansion and plasticdeformation. 124-126. (canceled)
 127. A method of radially expanding andplastically deforming a tubular assembly comprising a first tubularmember coupled to a second tubular member, comprising: radiallyexpanding and plastically deforming the tubular assembly within apreexisting structure; and using less power to radially expand each unitlength of the first tubular member than to radially expand each unitlength of the second tubular member. 128-134. (canceled)
 135. A methodof manufacturing a tubular member, comprising: processing a tubularmember until the tubular member is characterized by one or moreintermediate characteristics; positioning the tubular member within apreexisting structure; and processing the tubular member within thepreexisting structure until the tubular member is characterized one ormore final characteristics. 136-141. (canceled)
 142. An apparatus,comprising: an expandable tubular assembly; and an expansion devicecoupled to the expandable tubular assembly; wherein a predeterminedportion of the expandable tubular assembly has a lower yield point thananother portion of the expandable tubular assembly. 143-189. (canceled)190. An expandable tubular member, wherein a yield point of theexpandable tubular member after a radial expansion and plasticdeformation is at least about 5.8% greater than the yield point of theexpandable tubular member prior to the radial expansion and plasticdeformation. 191-193. (canceled)
 194. A method of determining theexpandability of a selected tubular member, comprising: determining ananisotropy value for the selected tubular member; determining a strainhardening value for the selected tubular member; and multiplying theanisotropy value times the strain hardening value to generate anexpandability value for the selected tubular member. 195-198. (canceled)199. A method of radially expanding and plastically deforming tubularmembers, comprising: selecting a tubular member; determining ananisotropy value for the selected tubular member; determining a strainhardening value for the selected tubular member; multiplying theanisotropy value times the strain hardening value to generate anexpandability value for the selected tubular member; and if theanisotropy value is greater than 0.12, then radially expanding andplastically deforming the selected tubular member. 200-204. (canceled)205. A radially expandable tubular member apparatus comprising: a firsttubular member; a second tubular member engaged with the first tubularmember forming a joint; and a sleeve overlapping and coupling the firstand second tubular members at the joint; wherein, prior to a radialexpansion and plastic deformation of the apparatus, a predeterminedportion of the apparatus has a lower yield point than another portion ofthe apparatus. 206-309. (canceled)
 310. A method of joining radiallyexpandable tubular members comprising: providing a first tubular member;engaging a second tubular member with the first tubular member to form ajoint; providing a sleeve; mounting the sleeve for overlapping andcoupling the first and second tubular members at the joint; wherein thefirst tubular member, the second tubular member, and the sleeve define atubular assembly; and radially expanding and plastically deforming thetubular assembly; wherein, prior to the radial expansion and plasticdeformation, a predetermined portion of the tubular assembly has a loweryield point than another portion of the tubular assembly. 311-666.(canceled)
 667. A method of selecting tubular members for radialexpansion and plastic deformation, comprising: selecting a tubularmember from a collection of tubular member; determining a carbon contentof the selected tubular member; determining a carbon equivalent valuefor the selected tubular member; if the carbon content of the selectedtubular member is less than or equal to 0.12 percent and the carbonequivalent value for the selected tubular member is less than 0.21, thendetermining that the selected tubular member is suitable for radialexpansion and plastic deformation; and if the carbon content of theselected tubular member is greater than 0.12 percent and the carbonequivalent value for the selected tubular member is less than 0.36, thendetermining that the selected tubular member is suitable for radialexpansion and plastic deformation. 668-672. (canceled)
 673. Anexpandable tubular member, comprising: a tubular body; wherein a yieldpoint of an inner tubular portion of the tubular body is less than ayield point of an outer tubular portion of the tubular body. 674-728.(canceled)
 729. A method of manufacturing an expandable tubular member,comprising: providing a tubular member; heat treating the tubularmember; and quenching the tubular member; wherein following thequenching, the tubular member comprises a microstructure comprising ahard phase structure and a soft phase structure. 730-757. (canceled)758. An expansion device for radially expanding and plasticallydeforming a tubular member comprising: an elongated base member; and anadjustable expansion assembly moveably coupled to the elongated basemember, the adjustable expansion assembly comprising a plurality ofexpansion segment operable to expand the adjustable expansion assemblyin diameter, wherein throughout the expansion at least a portion of theexpansion segments overlap in the circumferential direction. 759-805.(canceled)
 806. A method for radially expanding and plasticallydeforming a tubular member comprising: providing a tubular member, thetubular member defining a passage therein; locating an expansion devicein the passageway defined by the tubular member, the expansion devicecomprising an adjustable expansion assembly, the adjustable expansionassembly comprising a plurality of expansion segments operable to expandthe adjustable expansion assembly in diameter, wherein throughout theexpansion at least a portion of the plurality of expansion segmentsoverlap in the circumferential direction; expanding the adjustableexpansion assembly; displacing the expansion device along a longitudinalaxis through the tubular member; and radially expanding and plasticallydeforming the tubular member along the longitudinal axis. 807-812.(canceled)
 813. An expandable tubular member comprising a steel alloycomprising, by weight percentage, the following: 0.065 to 0.18% C, 0.006to 1.44% Mn, 0.006 to 0.02% P, 0.001 to 0.004% S, 0.24 to 0.45% Si, upto 0.16% Cu, 0.01 to 9.1% Ni, and 0.02 to 18.7% Cr.
 814. An expandabletubular member, wherein the yield point of the expandable tubular memberis at most about 46.9 to 61.7 ksi prior to a radial expansion andplastic deformation; and wherein the yield point of the expandabletubular member is at least about 65.9 to 74.4 ksi after the radialexpansion and plastic deformation.
 815. An expandable tubular member,wherein a yield point of the expandable tubular member after a radialexpansion and plastic deformation is at least about 5.8 to 40% greaterthan the yield point of the expandable tubular member prior to theradial expansion and plastic deformation.
 816. An expandable tubularmember, wherein the anisotropy of the expandable tubular member, priorto the radial expansion and plastic deformation, ranges from about 1.04to at least about 1.92.
 817. An expandable tubular member, wherein theexpandability coefficient of the expandable tubular member, prior to theradial expansion and plastic deformation, is greater than 0.12.
 818. Anexpandable tubular member, wherein, if the carbon content of the tubularmember is less than or equal to 0.12 percent, then the carbon equivalentvalue for the tubular member is less than 0.21; and wherein, if thecarbon content of the tubular member is greater than 0.12 percent, thenthe carbon equivalent value for the tubular member is less than 0.36.819. A method of increasing a collapse strength of a tubular memberafter a radial expansion and plastic deformation of the tubular memberusing an expansion device, comprising: reducing a coefficient offriction between the tubular member and the expansion device during theradial expansion and plastic deformation of the tubular member; andreducing a ratio of a diameter of the tubular member to a wall thicknessof the tubular member.
 820. A system for radially expanding andplastically deforming a tubular member, comprising: a tubular member;and an expansion device positioned within the tubular member; whereinthe coefficient of friction between the tubular member and the expansiondevice is less than 0.075; and wherein the ratio of the diameter of thetubular member to a wall thickness of the tubular member is less than21.6.
 821. A method of radially expanding and plastically deforming atubular member using an expansion device, comprising: quenching andtempering the tubular member; positioning the tubular member within apreexisting structure; and radially expanding and plastically deformingthe tubular member.
 822. A radially expandable and plasticallydeformable tubular member, comprising: a yield strength ranging fromabout 40.0 ksi to 100.0 ksi; a ratio of the yield strength to a tensilestrength of the tubular member ranging from about 0.40 to 0.86; alongitudinal elongation of the tubular member prior to failure rangingfrom about 14.8% to 35.0%; a width reduction of the tubular member priorto failure ranging from about 30% to 45.0%; a width thickness reductionof the tubular member prior to failure ranges from about 30.0% to 45%;and an anisotropy of the tubular member ranges from about 0.65 to 1.50.823. A method of manufacturing a tubular member, comprising: fabricatinga tubular member having intermediate properties; positioning the tubularmember within a preexisting structure; radially expanding andplastically deforming the tubular member within the preexistingstructure; and baking the tubular member within the preexistingstructure to convert one or more of the intermediate properties to finalproperties.